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YAMAHA 



YFM350X 
WARRIOR 




YAMAHA 



YFM350XKC 

(for California) 



SUPPLEMENTARY 
SERVICE MANUAL 



LIT-11616-10-89 3GD-28197-15 



FOREWORD 



This Supplementary Service Manual has been prepared to introduce new service and data 
for the YFM350XKC. For complete service information procedures, it is necessary to use this 
Supplementary Service Manual together with the following manual. 



YFM350XA SERVICE MANUAL (LIT-1 1616-07-50) 
YFM350XE SUPPLEMENTARY SERVICE MANUAL {LIT-1 1616-08-60) 
YFM350XJ SUPPLEMENTARY SERVICE MANUAL {LIT-1 1616-10-28) 



YFM350XKC 

SUPPLEMENTARY 

SERVICE MANUAL 

©1997 by Yamaha Motor Corporation, U.S.A. 

First Edition, April 1997 

All rights reserved. Any reproduction or 

unauthorized use without the written 

permission of Yamaha Motor Corporation, U.S.A. 

is expressly prohibited. 

Printed in U.S.A. 

LIT-1 1616-10-89 



NOTICE 

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha 
dealers and their qualified mechanics. It is not possible to include all the knowledge of a 
mechanic in one manual, so it is assumed that anyone who uses this book to perform main- 
tenance and repairs on Yamaha machines has a basic understanding of the mechanical ideas 
and the procedures of machine repair. Repairs attempted by anyone without this knowledge 
are likely to render the machine unsafe and unfit for use. 

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications 
and significant changes in specifications or procedures will be forwarded to all authorized 
Yamaha dealers and will appear in future editions of this manual where applicable. 



NOTE: 

Designs and specifications are subject to change without notice. 



IMPORTANT INFORMATION 

Particularly important information is distinguished in this manual by the following notations. 

A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 

SAFETY IS INVOLVED! 

Failure to follow WARNING instructions could result in severe injury or 
death to the machine operator, a bystander or a person inspecting or 
repairing the machine. 

A CAUTION indicates special precautions that must be taken to avoid 
damage to the machine. 

A NOTE provides key information to make procedures easier or clearer. 



A WARNING 



CAUtlON; 



NOTE: 



HOW TO USE THIS MANUAL 

MANUAL ORGANIZATION 

This manual is intended as a handy, easy-to-read reference book for the mechanic. It is 
divided into chapters, sections and sub-sections. Comprehensive explanations of all installa- 
tion, removal, disassembly, assembly, repair and inspection procedures are laid out with the 
individual steps in sequential order. 
PAGE FEATURES 

The circled numbers below refer to the features indicated in the sample page. 
: An abbreviation and symbol in the upper right corner of each page indicates the current 
chapter. 

(D : The current section title is shown at the top of each page.t 

(D : Sub-section titles appear in smaller print than the section title.t 

: Lines of asterisks (*) mark the beginning and end of a particularly important procedure. 
The steps of such procedures are marked with bullets (•). 

(§) : Important information such as fluids, special tools and torques are framed and marked 
with a corresponding symbol. 

(?) : A circled number refers to an illustrated part. 

(?) : A circled lower case letter refers to an illustrated dimension or alignment mark. 

(D : An upper case letter in a box refers to other illustrated details. 

<D : An arrow mark after a given defect suggests the recommended course of action. 

t : In Chapter 3, "Periodic Inspection and Adjustment", it is usually the current sub-section 
title that appears at the top of each page, instead of the current section title. 

EXPLODED DIAGRAMS 

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of 
each disassembly section. 




turiac* nt+ e ¥*•#•* h» 










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FRONT FORK CHAS|<#36> 




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7& 


'«! IKtaf !•— H*tt* 


-K 


lUnWIM 




MUMWMIW fl*« Mftfl* 




*»»W.1» ID 




© 



GEN 
INFO 



<£« 



© 



INSP 



ADJ 



<& 



© 



CARB 



¥ 



© 





© 






© 



SPEC 



© 



ENG 



M 



© 



DRIV 



-)o 



© 




© 








CHAS 


&6 


ELEC 


LJ 


CD 


© 


>*t 




TRdL 
SHTG 


9 

• 




<J 






© 




Si 

1 t— TT 



© 



i 



i 



1 



® 



A 



® 



New 



ILLUSTRATED SYMBOLS 

Illustrated symbols © to (9) are printed on 
the top right of each page and indicate the 
subject of each chapter. 

© General information 

© Specifications 

© Periodic inspections and adjustments 

© Engine 

© Carburetion 

© Drive train 

© Chassis 

© Electrical 

©Troubleshooting 



Illustrated symbols (§) to (§) are used to 
identify the specifications appearing in the 
text. 

© Filling fluid 

© Lubricant 

© Special tool 

©Torque 

© Wear limit, clearance 

© Engine speed 

© Q, V, A 



Illustrated symbols © to (g) in the exploded 
diagrams indicate the types of lubricants 
and lubrication points. 

©Apply engine oil 

©Apply gear oil 

© Apply molybdenum disulfide oil 

© Apply wheel bearing grease 

© Apply lightweight lithium-soap base grease 

© Apply molybdenum disulfide grease 

Illustrated symbols @ to @ in the exploded 

diagrams indicate where to apply a locking 

agent ® and when to install a new part ©. 

® Apply the locking agent (LOCTITE®) 
@ Replace 



CONTENTS 



SPECIFICATIONS 1 

GENERAL SPECIFICATIONS 1 

MAINTENANCE SPECIFICATIONS 1 

ENGINE 1 

PERIODIC INSPECTIONS AND ADJUSTMENTS 2 

INTRODUCTION 2 

PERIODIC MAINTENANCE/LUBRICATION 2 



GENERAL SPECIFICATIONS/ 
MAINTENANCE SPECIFICATIONS 



SPEC 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



Model 



YFM350XKC 



Model code: 



3GDM 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Model 


YFM350XKC 


Carburetor: 






1. D. mark 




3GD10 


Main jet 


(M.J) 


#145 


Main air jet 


(M.A.J) 


0.6 


Jet needle 


(J.N) 


5J31 


Needle jet 


(N.J) 


0-6M 


Pilot air jet 


(P.AJ.1) 


1.0 


Pilot air jet 


(P.A.J.2) 


0.7 


Pilot outlet 


(P.O) 


0.75 


Pilot jet 


(P.J) 


#42.5 


Bypass 1 


(B.P.I) 


0.8 


Bypass 2 


(B.P.2) 


0.8 


Bypass 3 


(B.P.3) 


0.8 


Pilot screw 


(P.S) 


2 


Valve seat size 


(V.S) 


2.5 


Starter jet 


(G.S.1) 


#62.5 


Throttle valve size 


(Th.V) 


#125 


Float height 


(F.H) 


11.4- 13.4 mm (0.45 -0.53 in) 


Fuel level 


(F.L) 


2 -3mm (0.08- 0.12 in) 


Engine idle speed 




1,450 - 1,550 r/min 


Intake vacuum 




30.7 kPa (0.307 kg/cm 2 , 4.4 psi) 



-1_ 



INTRODUCTION/ 
PERIODIC MAINTENANCE/LUBRICATION 



INSP 



ADJ 



<& 



PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perform recommended inspections and 
adjustments. These preventive maintenance procedures, if followed, will ensure more reli- 
able machine operation and a longer service life. In addition, the need for costly overhaul 
work will be greatly reduced. This information applies to machines already in service as well 
as new machines that are being prepared for sale. All service technicians should be familiar 
with this entire chapter. 

PERIODIC MAINTENANCE/LUBRICATION 



rrEM 




INITIAL 


EVERY 


ROUTINE 


1 
month 


3 
months 


6 
months 


6 
months 


1 

year 


Valves* 


♦ Check valve clearance. 

• Adjust if necessary. 


o 




o 


o 


o 


Spark plug 


• Check condition. 

• Adjust gap and clean. 

• Replace if necessary. 


o 


o 


o 


o 


o 


Air filter 


• Clean. 

• Replace if necessary. 


Every 20-40 hours 
(More often in wet or dusty areas.) 


Carburetor* 


• Check and adjust idle speed/starter operation. 

• Adjust if necessary. 




o 


o 


o 


o 


Crankcase breather 
system* 


• Check breather hose for cracks or damage. 

• Replace if necessary. 






o 


o 


o 


Exhaust system* 


• Check for leakage. 

• Retighten if necessary. 

• Replace gasket if necessary. 






o 


o 


o 


Fuel line* 


• Check fuel hose for cracks or damage. 

• Replace if necessary. 






o 


o 


o 


Engine oil 


* Replace (Warm engine before draining.) 







o 


o 


o 


Engine oil filter 


• Clean. 

• Replace if necessary. 






o 


o 


o 


Engine oil strainer 


• Clean. 


o 




o 




o 


Drive chain 


• Check and adjust slack/alignment/clean/lube. 


o 


o 


o 








Brake* 


♦ Check operation/fluid leakage/See NOTE. 

• Correct if necessary. 


o 





o 


o 


o 


Clutch* 


• Check operation. 

• Adjust if necessary. 


o 




o 


o 


o 


Wheels* 


• Check balance/damage/runout. 

• Replace if necessary. 


o 




o 


o 


o 


Wheel bearings* 


• Check bearing assembly for looseness/damage. 

• Replace if damaged. 


o 




o 


o 


o 


Steering system* 


• Check operation, 

• Repair if damaged. 

• Check toe-in. 

• Adjust if necessary. 


o 


o 


o 


o 


o 


Upper and lower arm 
pivot and steering 
shaft* 


• Lubricate every 6 months.** 






o 


o 


o 


Rear arm pivot* 


• Lubricate every 6 months.** 






o 


o 


o 



-2- 



PERIODIC MAINTENANCE/LUBRICATION 



INSP 
ADJ 






ITEM 


ROUTINE 


INITIAL 


EVERY 


1 
month 


3 
months 


6 
months 


6 
months 


1 
year 


Fittings and Fasteners* 


• Check all chassis fittings and fasteners. 

• Correct if necessary. 


o 


o 


o 


o 


o 


Battery* 


• Check specific gravity. 

• Check breather pipe for proper operation. 

• Correct if necessary. 


o 


o 


o 


o 


o 



* : It is recommended that these items be serviced by a Yamaha dealer. 
** : Lithium soap base grease. 



NOTE: 

Brake fluid replacement: 

1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. 
Normally check the brake fluid level and add fluid as required. 

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every 
two years. 

3. Replace the brake hoses every four years, or if cracked or damaged. 



A WARNING 



Indicates a potential harzard that could result in serious injuly or death. 



-3- 



YAMAHA 



YFM350XJ 



SUPPLEMENTARY 
SERVICE MANUAL 



UT-1 161 6-1 0-28 



FOREWORD 



This Supplementary Service Manual has been prepared to introduce new service and data 
for the YFM350XJ. For complete service information procedures, it is necessary to use this 
Supplementary Service Manual together with the following manual. 



YFM350XA SERVICE MANUAL (LIT-1 1616-07-50) 
YFM350XE SUPPLEMENTARY SERVICE MANUAL (LIT-1 1616-08-60) 



YFM350XJ 

SUPPLEMENTARY 

SERVICE MANUAL 

©1996 by Yamaha Motor Corporation, U.S.A. 

First Edition, July 1996 

All rights reserved. Any reproduction or 

unauthorized use without the written 

permission of Yamaha Motor Corporation, U.S.A. 

is expressly prohibited. 

Printed in U.S.A. 

LIT-1 1616-10-28 



NOTICE 

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha 
dealers and their qualified mechanics. It is not possible to include all the knowledge of a 
mechanic in one manual, so it is assumed that anyone who uses this book to perform main- 
tenance and repairs on Yamaha machines has a basic understanding of the mechanical ideas 
and the procedures of machine repair. Repairs attempted by anyone without this knowledge 
are likely to render the machine unsafe and unfit for use. 

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications 
and significant changes in specifications or procedures will be forwarded to all authorized 
Yamaha dealers and will appear in future editions of this manual where applicable. 



NOTE: 

Designs and specifications are subject to change without notice. 



IMPORTANT INFORMATION 

Particularly important information is distinguished in this manual by the following notations. 

A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 

SAFETY IS INVOLVED! 

Failure to follow WARNING instructions could result in severe injury or 
death to the machine operator, a bystander or a person inspecting or 
repairing the machine. 

A CAUTION indicates special precautions that must be taken to avoid 
damage to the machine. 

NOTE: A NOTE provides key information to make procedures easier or clearer. 



ik WARNING 



HOW TO USE THIS MANUAL 

MANUAL ORGANIZATION 

This manual is intended as a handy, easy-to-read reference book for the mechanic. It is 
divided into chapters, sections and sub-sections. Comprehensive explanations of all installa- 
tion, removal, disassembly, assembly, repair and inspection procedures are laid out with the 
individual steps in sequential order. 
PAGE FEATURES 

The circled numbers below refer to the features indicated in the sample page. 
: An abbreviation and symbol in the upper right corner of each page indicates the current 
chapter. 

(D : The current section title is shown at the top of each page.t 

: Sub-section titles appear in smaller print than the section title.t 

: Lines of asterisks <*) mark the beginning and end of a particularly important procedure. 
The steps of such procedures are marked with bullets (•). 

: Important information such as fluids, special tools and torques are framed and marked 
with a corresponding symbol. 

: A circled number refers to an illustrated part. 

: A circled lower case letter refers to an illustrated dimension or alignment mark. 

: An upper case letter in a box refers to other illustrated details. 

: An arrow mark after a given defect suggests the recommended course of action. 

t : In Chapter 3, "Periodic Inspection and Adjustment", it is usually the current sub-section 
title that appears at the top of each page, instead of the current section title. 

EXPLODED DIAGRAMS 

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of 
each disassembly section. 




© 



GEN 
INFO 



c^5 



® 



INSP 



ADJ 



<& 



® 



CARB 






<D 



SPEC 



© 



ENG 



%1 



® 



© 



CHAS 



^6 



® 



TRBL 
SHTGI 



© 





% 




DRIV 



■fr 



© 



ELEC 



® 



<0 




<g) 





© 



i 



1 



1 



® 



A 



New 



ILLUSTRATED SYMBOLS 

Illustrated symbols to (9) are printed on 
the top right of each page and indicate the 
subject of each chapter. 

© General information 

(D Specifications 

© Periodic inspections and adjustments 

©Engine 

© Carburetion 

© Drive train 

© Chassis 

© Electrical 

© Troubleshooting 



Illustrated symbols <@ to <© are used to 
identify the specifications appearing in the 
text. 

® Filling fluid 

(Fj) Lubricant 

<g> Special tool 

(§) Torque 

(g) Wear limit, clearance 

@ Engine speed 

<© a V, A 



Illustrated symbols © to (^) in the exploded 
diagrams indicate the types of lubricants 
and lubrication points. 

©Apply engine oil 

©Apply gear oil 

<® Apply molybdenum disulfide oil 

(g> Apply wheel bearing grease 

© Apply lightweight lithium-soap base grease 

<g> Apply molybdenum disulfide grease 

Illustrated symbols @> to @ in the exploded 

diagrams indicate where to apply a locking 

agent @> and when to install a new part @. 

<§> Apply the locking agent {LOCTITE®) 
@ Replace 



CONTENTS 



GENERAL INFORMATION 

MACHINE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

ENGINE SERIAL NUMBER 

MODEL LABEL 



SPECIFICATIONS 2 

GENERAL SPECIFICATIONS... 2 

MAINTENANCE SPECIFICATIONS 3 

ENGINE 3 

ELECTRICAL 4 

CABLE ROUTING 5 

PERIODIC INSPECTIONS AND ADJUSTMENTS 9 

INTRODUCTION 9 

PERIODIC MAINTENANCE/LUBRICATION 9 

ELECTRICAL 11 

IGNITION SYSTEM 11 

CIRCUIT DIAGRAM 11 

ENGINE REVOLUTION LIMITER SYSTEM 12 

YFM350X WIRING DIAGRAM 



MACHINE IDENTIFICATION 



GEN 
INFO 



<$% 




GENERAL INFORMATION 
MACHINE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number © is 
stamped into the left side of the frame. 



NOTE: 

The vehicle identification number is used to 
identify the machine and may be used to 
register the machine with a licensing 
authority. 




ENGINE SERIAL NUMBER 

The engine serial number is stamped 
into the right side of the frame. 



MODEL LABEL 

The model label is affixed to the frame. 
This information will be needed to order 
spare parts. 



_1 



GENERAL SPECIFICATIONS 



SPEC 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



Model 



YFM350X 



Model code: 



3GDK 



Engine: 
Engine type 
Cylinder arrangement 
Displacement 
Bore x stroke 
Compression ratio 
Compression pressure (STD) 
Starting system 



Air-cooled 4-stroke, SOHC 

Forward-inclined single cylinder 

348 cm 3 

83.0 x 64.5 mm (3.27 x 2.54 in) 

9.2:1 

850 kPa {8.5 kg/cm 2 , 121 psi) at 350 r/min 

Electric and recoil starter 



Oil type or grade: 
Engine oil 



10 



30 



50 



70T 



c 



Yamalube4 (10W30) or SAE 10W30 



SAE 5W30 



2 



<i 



ZL 



Yamalube 4 (20W40) or SAE 20W40 



Yamalube 4 or SAE10W30 type SE motor oil, 
or SAE20W40 type SE motor oil 



-10 



10 



20°C 



Tire: 
Type 
Size 

Manufacturer 

Type 



front 

rear 

front 

rear 

front 

rear 



Tubeless 

AT22x7-10 

AT22x10-9 

DUNLOP 

DUNLOP 

KT701 

KT775B 



Tire pressure (cold tire): 
Off-road riding 



front 
rear 



22 
22 



28 kPa (0.22 ~ 0.28 kg/cm 2 , 3.13 ~ 3.98 psi) 
28 kPa {0.22 ~ 0.28 kg/cm 2 , 3.13 ~ 3.98 psi) 



Brake: 
Front brake 

Rear brake 



type 

operation 
type 
operation 



Disc brake 

Right hand operation 

Disc brake 

Left hand and right foot operation 



Bulb wattage x quantity: 
Headlight 
Taillight 
NEUTRAL 
REVERSE 



12V30W/30Wx2 
12V3.8Wx1 
12V3.4Wx1 
12V3.4Wx1 



-2- 



MAINTENANCE SPECIFICATIONS 


SPEC 


0- 


MAINTENANCE SPECIFICATIONS 




ENGINE 






Model 


YFM350X 


Crankshaft: 


F 
I 1 ' 




%ri] 


1» 




T' 


^y 


1* 


AH 




Crank width "A" 




58.95 ~ 59.00 mm (2.321 ~ 2.323 in) 


Runout limit "C" 




0.06 mm (0.0024 in) 


Big end side clearance "D" 




0.35 - 0.85 mm (0.014 - 0.033 in) 


Big end radial clearance "E 


a 


0.010 ~ 0.025 mm (0.0004 - 0.0010 in) 


Small end free play "F" 




0.8 - 1.0 mm (0.03 - 0.04 in) 


<Limit> 




<2 mm (0.08 in)> 


Carburetor: 






1. D. mark 




3GD00 


Main jet 


(M.J) 


#145 


Main air jet 


(M.AJ) 


0.6 


Jet needle 


(J.N) 


5J18-3 


Needle jet 


(N.J) 


0-6 


Pilot air jet 


(P.A.J.1) 


1.0 


Pilot air jet 


(P.A.J.2) 


0.7 


Pilot outlet 


(P.O) 


0.75 


Pilot jet 


(P.J) 


#42.5 


Bypass 1 


(B.P.1) 


0.8 


Bypass 2 


(B.P.2) 


0.8 


Bypass 3 


(B.P.3) 


0.8 


Pilot screw 


(P.S) 


2 


Valve seat size 


(V.S) 


2.5 


Starter jet 


(G.S.I) 


#62.5 


Throttle valve size 


(Th.V) 


#125 


Float height 


(F.H) 


11.4- 13.4 mm (0.45 -0.53 in) 


Fuel level 


(F.L) 


2 -3 mm (0.08- 0.12 in) 


Engine idle speed 




1,450 - 1,550 r/min 


Intake vacuum 




34 kPa (0.34 kg/cm 2 , 4.8 psi) 



-3- 



MAINTENANCE SPECIFICATIONS 



SPEC 



ELECTRICAL 



Model 


YFM350X 


C.D.I.: 
Magneto model / manufacturer 
Pickup coil resistance / color 
Source coil resistance / color 
C.D.I, unit model / manufacturer 


F3T43573/MITSUBISHI 

459 - 561 Q at 20°C (68°F) / Red - White 

270 ~ 330 Q at 20"C (68T) / Brown - Green 

F8T34271/MITSUBISHI 


Voltage regulator: 
Type 

Model / manufacturer 
No lead regulated voltage 


Semi conductor-short circuit type 
SH640A-12/SHINDENGEN 
14.2- 15.2 V 


Rectifier: 
Model / manufacturer 
Capacity 
Withstand voltage 


SH640A-12/SHINDENGEN 
20 A 
240 V 



-4- 



CABLE ROUTING 



SPEC 



CABLE ROUTING 

Clutch switch 
(D Rear brake cable 
CD Clutch cable 
® Front brake hose 
<D Throttle cable 
(D Main switch lead 
Brake hose 

[a] Install the fuel tank breather hose into the hole 
of the handlebar cover. 




-5- 



© Fuel tank breather hose 

(2) Fuel hose 

® Crankcase breather hose 

(4) Starter relay 

(g) Starting circuit cut-off relay 

(D Neutral relay 

® CDI unit 

® Main fuse 

(§) Battery breather hose 

® CDI magneto lead 

(0) Neutral switch lead 



CABLE ROUTING 



SPEC 


U* - ■ 



13 Pass the air vent hose through hole on the fuel 

tank rubber damper. 
HO Pass the battery breather hose through the 

inside of frame bracket. 
[c] Pass the battery breather hose through the 

guide. 




-6- 



CABLE ROUTING 




Starter motor lead 
Starter motor 
Lever switch 
Rear brake cable 
Rear brake hose 
Rectifier/regulator 
CDI unit 
CDI unit lead 



[a] Pass the wire harness and starter motor lead 

through the holder. 
HD Fasten the wire harness, starter motor lead and 

handlebar switch lead with the band. 
[c] Route behind the starter motor lead. 
\d\ The leads should not protrude past the frame. 




-7 



CABLE ROUTING 



SPEC 



Ignition coil 

(D Headlight lead 

© Neutral indicator light 

(a] Align the marking tape on the wire harness 

with the clamp. 
HI Pass the battery leads through the hole on 

the rear fender. 




-8- 



INTRODUCTION/ 
PERIODIC MAINTENANCE/LUBRICATION 



INSP 



ADJ 






PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perform recommended inspections and 
adjustments. These preventive maintenance procedures, if followed, will ensure more reli- 
able machine operation and a longer service life. In addition, the need for costly overhaul 
work will be greatly reduced. This information applies to machines already in service as well 
as new machines that are being prepared for sale. All service technicians should be familiar 
with this entire chapter. 

PERIODIC MAINTENANCE/LUBRICATION 



ITEM 


ROUTINE 


INITIAL 


EVERY 


1 
month 


3 
months 


6 
months 


6 
months 


1 

year 


Valves* 


* Check valve clearance. 

• Adjust if necessary. 


o 




o 


o 





Spark plug 


* Check condition. 

• Clean or replace if necessary. 


o 


o 


o 


o 





Air filter 


• Clean. 

* Replace if necessary. 


Every 20~40 hours 
(More often in wet or dusty areas.) 


Carburetor* 


• Check idle speed/starter operation. 

• Adjust if necessary. 




o 


o 


o 


o 


Fuel line* 


• Check fuel hose for cracks or damage. 

• Replace if necessary. 






o 








Engine oil 


• Replace (Warm engine before draining). 


o 




o 


o 


o 


Engine oil filter 


• Clean. 

• Replace if necessary. 






o 


o 





Engine oil strainer 


• Clean. 







o 




o 


Drive chain 


• Check and adjust slack/alignment/clean/lube. 


o 


o 


o 


o 


o 


Brake* 


• Check operation/fluid leakage/See NOTE. 

* Correct if necessary. 





o 


o 


o 





Clutch* 


• Check operation. 

• Adjust if necessary. 


o 




o 


o 





Wheels* 


• Check balance/damage/runout. 

• Replace if necessary. 


o 




o 








Wheel bearings* 


• Check bearing assembly for looseness/damage. 

• Replace if damaged. 







o 


o 


o 


Steering system* 


• Check operation. 

• Repair if damaged. 

• Check toe-in. 

• Adjust if necessary. 


o 


o 


o 





o 


Upper and lower arm 
pivot and steering 
shaft* 


• Lubricate every 6 months.*** 















Rear arm pivot* 


• Lubricate every 6 months.*** 






o 





o 


Fittings/Fasteners* 


• Check all chassis fittings and fasteners. 

• Correct if necessary. 


o 


o 


o 








Battery* 


• Check specific gravity. 

• Check breather pipe for proper operation. 

• Correct if necessary. 


o 


o 


o 





o 



* : It is recommended that these items be serviced by a Yamaha dealer. 
***: Lithium soap base grease. 



-9- 



PERIODIC MAINTENANCE/LUBRICATION 



INSP 
ADJ 



<* 



NOTE: 

Brake fluid replacement: 

1 . When disassembling the master cylinder or caliper cylinder, replace the brake fluid. 
Normally check the brake fluid level and add fluid as required. 

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every 
two years. 

3. Replace the brake hoses every four years, or if cracked or damaged. 



-10- 



IGNITION SYSTEM 



tLtU 



ELECTRICAL 



IGNITION SYSTEM 

CIRCUIT DIAGRAM 



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11- 



IGNITION SYSTEM 



ELEC 



3 




ENGINE REVOLUTION LIMITER SYSTEM 

When the parking brake is applied, the 
engine revolution limiter system becomes 
activated, thereby letting the rider know 
that the parking brake is on. 

System 

A switch is newly provided on the parking 
brake lever on the left of the handlebar to 
sense the parking brake condition. 
The ignition unit which receives a sensed 
signal becomes activated as follows 
according to the parking brake condition. 



• Parking brake is released. 

(switch OFF) -> Ignition occurs normally. 

• Parking brake is applied, 
(switch ON) -» Misfire occurs at 

2300 r/min. 
(engine will not rev up beyond 
2300 r/min.) 



© CDI unit 

© Ignition timing control circuit 

(3) Parking switch 



12- 



go 




?s 



O£c2u.CQC0C0C0OO S>V> Q.OZ-jZZtE£EXf-X 

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L - HE3<J-©-CD<l- - -t 



YAMAHA 

YAMAHA MOTOR CO., LTD. 

2500 SHINGAI IWATA SHIZUOKA JAPAN 



PRINTED IN U.S.A. 



YAMAHA 



YFM350XE 



SUPPLEMENTARY 
SERVICE MANUAL 







LIT-1 1616-08-60 



FOREWORD 

This Supplementary Service Manual has been prepared to introduce new service and data for the 
YFM350XE, For complete service information procedures, it is necessary to use this Supplementary 
Service Manual together with the following manual. 



YFM350XA Service Manual (LIT-1 1616-07-50) 



YFM350XE 

SUPPLEMENTARY 

SERVICE MANUAL 

© 1992 by Yamaha Motor Corporation, U.S.A, 

1st Edition, July 1992 

All rights reserved. Any reprinting or 

unauthorized use without the written permission 

of Yamaha Motor Corporation, U.S.A, 

is expressly prohibited. 

Printed in U.S.A. 

LIT-1 161 6-08-60 



NOTICE 

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it 
is assumed that persons using this book to perform maintenance and repairs on Yamaha machines 
have a basic understanding of the mechanical concepts and procedures inherent in machine repair 
technology. Without such knowledge, attempted repairs or service to this model may render it unfit to 
use and/or unsafe. 

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. 
Modifications and significant changes in specifications or procedures will be forwarded to all Auth- 
orized Yamaha dealers and will, where applicable, appear in future editions of this manual. 



PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 



A 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED! 



AWARNING 



Failure to follow WARNING instructions could result in severe injury or death 
to the machine operator, a bystander, or a person inspecting or repairing the 
machine. 



A CAUTION indicates special precautions that must be taken to avoid damage 
to the machine. 



NOTE: 



A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

CONSTRACTION OF THIS MANUAL 

This manual consists of chapters for the main categories of subjects. (See "illustrated symbols") 



1st title (D 
2nd title (2) 

3rd title (D 



This is a chapter with its symbol on the upper right of each page. 

This title appears on the upper of each page on the left of the chapter 
symbol. (For the chapter "Periodic inspection and adjustment" the 3rd 
title appears.) 

This is a final title. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The infor- 
mation has been compiled to provide the mechanic with an easy to read, handy reference that 
contains comprehensive explanations of all disassembly, repair, assembly, and inspections. 
A set of particularly important procedure ® is placed between a line of asterisks "*" with each 
procedure preceded by " • ". 

IMPORTANT FEATURES 

• Data and a special tool are framed in a box preceded by a relevant symbol (D . 

• An encircled numeral © indicates a part name, and an encircled alphabetical letter data or an 
alignment mark (7) , the others being indicated by an alphabetical letter in a box ® . 

• A condition of a faulty component will precede an arrow symbol and the course of action re- 
quired the symbol (§) . 



EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identif- 
ying correct disassembly and assembly procedures. 





Take care to avoide damaging the sp 
threads. Do not use a shaip inst 


'1^ 


■ Cylinder head warpage 
Out of specification -* Resurface. 


s 


Warpage limit: I 
02 mm 10.001 In) J 





Warpage maaauramanl and r»»t 
rnant il«p: 

* Attach a straight edge G> and air 
Si gauge ^ on The cylinder head 



surface 


the 


cylind* 


head. 




* Place a 


400 


- 600 


lit wq 


< sandpaper an 


the fur 


ace 


plate, a 


idrea 


rface The heari 


using 9 


fjgu 


e eight 




pattern. 












Rome t 


ehi 


ad save 


ral tim 


es to avoid re- 


mewing t 


om 


jch mat *rrial from one side. 





•Fork 


spring free length ®"^* 


Ouio 


(specifications Replace. 


Ak 


Fork spring Iraa length: 


^"N 


4l8.5mm<16,5ln> 




Minimum Iraa length: 




410 mm 116.1 in) 




® 


© 


GEN ^3» 
INFO 0^0 


SPEC 


Pf 


® 


© 


INSP g 


F9 


ENG 


A 
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ADJ ■ 


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SHTG 


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© 


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© 


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5©5 




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© © @ 

i l i 

Q Q 


@ @ <&> 

ri55E_ ^E^_ ^mSE_ 



ILLUSTRATED SYMBOLS 
(Refer to the illustration) 

Illustrated symbols (T) to ® are designed as 

thumb tabs to indicate the chapter's number and 

content. 

CD General information 

(2) Specifications 

® Periodic inspection and adjustment 

(?) Engine 

© Cooling system 

(6) Carburetion 

(?) Drive train 

® Chassis 

® Electrical 

© Troubleshooting 



Illustrated symbols © to © are used to identify 

the specifications appearing in the text. 

© Filling fluid 

© Lubricant 

© Special tool 

© Tightening 

© Wear limit, clearance 

© Engine speed 

© fi, V, A 



Illustrated symbols @ to © in the exploded dia- 
gram indicate grade of lubricant and location of 
lubrication point. 

© Appply locking agent (LOCTITE®) 

© Apply engine oil 

® Apply gear oil 

<£D Apply molybdenum disulfide oil 

@ Apply wheel bearing grease 

© Apply lightweight lithium-soap base grease 

@) Apply molybdenum disulfide grease 



CONTENTS 



GENERAL INFORMATION 1 

MACHINE IDENTIFICATION 1 

VEHICLE IDENTIFICATION NUMBER 1 

ENGINE SERIAL NUMBER 1 

SPECIFICATIONS 2 

GENERAL SPECIFICATIONS 2 

MAINTENANCE SPECIFICATIONS 2 

CHASSIS 2 

CABLE ROUTING 3 

PERIODIC INSPECTIONS AND ADJUSTMENTS 5 

THROTTLE CABLE ADJUSTMENT 5 



MACHINE IDENTIFICATION 



GEN 
INFO 



^5 




GENERAL INFORMATION 
MACHINE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number (J) is stamped 
into the left side of the frame. 



Starting serial number: 
JY43GDA0*PA095101 



NOTE: 



The vehicle identification number is used to 
identify your machine and may be used to regis- 
ter your machine with the licensing authority in 
your state. 






1* jfySjm *■■ 



ENGINE SERIAL NUMBER 

The engine serial number (J) is stamped into the 
right side the engine. 



Starting serial number: 
3GD-095101 



NOTE: 



•The first three digits of these numbers are for 
model identifications; the remaining digits are 
the unit production number. 

•Designs and specifications are subject to 
change without notice. 




GENERAL SPECIFICATIONS/ 
MAINTENANCE SPECIFICATIONS 



SPEC p9 



SPECIFICATIONS 



GENERAL SPECIFICATIONS 



Model 


YFM350XE 


Model code number 


3GDB 


Vehicle identification number 


JY43GDA0*PA095101 


Engine starting number 


3GD-095101 


Fuel: 
Type 

Tank capacity 
Reserve amount 


Regular gasoline 

9.0 L (2.0 Imp gal, 2.4 US gal) 

1.9 L (0.4 Imp gal, 0.5 US gal) 


Bulb wattage/Quantity: 
Headlight 
Taillight 
Neutral light 
Reverse light 


30W/30WX2 
7.5WX1 
3.4WX1 
3.4WX1 



MAINTENANCE SPECIFICATIONS 
CHASSIS 



Model 


YFM350XE 


Wheel: 




Front wheel type 


Panel wheel 


Rear wheel type 


Panel wheel 


Front rim size/Material 


10X6/ Aluminum 


Rear rim size/Material 


9X8.5/Aluminum 


Rim runout limit: 




Vertical 


<2.0 mm (0.08 in)> 


Lateral 


<2.0 mm (0.08 in)> 



-2- 



CABLE ROUTING 

Brake hose 
(D Clutch cable 
(D Brake cable 
(?) Throttle cable 
(§) Main switch 



CABLE ROUTING 



SPEC 09 



[A] Route outside the clamp and between the 

wireharness and the frame pipe. 
\B\ Route inside the throttle cable and brake hose. 




CABLE ROUTING 



SPEC 09 



® Ground bolt 


(Q) Neutral switch relay 


m 


(D Headlight 


# Fuse holder 




(f) Main switch lead 


(f§) Taillight lead guide 




(J) Clutch switch lead 


# Taillight unit 


LfJ 


(5) Handlebar switch lead 


@) Battery breather hose 




(D Band 


@ Rubber boot 




(J) Main switch 


@> Reservoir hose 


|G| 


(|) Pilot lamp 


(§> Clamp 




(9) Fuel tank breather hose 


{^ Neutral switch lead 


y 


© Fuel hose 


@ CDI magneto lead 


LU 


(Q) Air vent hose 


El Pass the headlight leads through 


S 


(&) Crankcase breather hose 


the hole on the headlight stay. 


IKJ 


(§) Ground lead 


[ID Clamp the leads securely and the 




<Q) Carburetor overflow hose 


band must be tight. 


LU 


(g) Starter relay 


El Install the main switch on the 




(jj) Starting circuit cut-off relay 


right side of the front panel. 






Pass the air vent hose through 


|Mj 




the hole on the fuel tank rubber 






damper. 





Pass the carburetor overflow 

hose between the rear arm head 

pipe and the rear shock absorber. 

Pass the carburetor overflow 

hose through the holder on the 

frame. 

Pass the brake hose along the 

curve of the cleaner case. 

Clamp the cable lead. 

Clamp the CDI magneto lead. 

Route behind the breather pipe. 

Pass the throttle cable through 

the holder. 

Pass the battery breather hose 

through the inside of frame 

bracket. 

Pass the battery breather hose 

through the holder. 




-4- 



THROTTLE CABLE ADJUSTMENT 



INSP 


m 


ADJ 



PERIODIC 
INSPECTIONS AND 
ADJUSTMENTS 
THROTTLE CABLE ADJUSTMENT 

NOTE: 

Please insert the following step in place of the 
corresponding part of the 3rd step. 




Adjustment steps: 
First step: 

• Loosen the locknut ®. 

• Turn the adjuster (2) in or out until the speci- 
fied free play is obtained. 



Turning in->Free play is increased. 



Turning out— Free play is decreased. 



Tighten the locknut. 



V 



\ 



Locknut: 

1 Nm(0.1 m. kg, 0.7 ft. lb) 



NOTE: 



If the free play cannot be adjusted here, adjust it 
at the throttle lever side of the cable. 



5- 



YAMAHA MOTOR CO.,LTD. 



PRINTED IN U.S. A 



YFM350XA 

SERVICE MANUAL 

©1990 by Yamaha Motor Corporation, U.S.A. 

1st Edition, May 1990 

All rights reserved. Any reprinting or 

unauthorized use without the written permission 

of Yamaha Motor Corporation, U.S.A. 

is expressly prohibited. 

Printed in U.S.A. 

LIT-1 1616-07-50 



NOTICE 

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, 
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machines 
have a basic understanding of the mechanical concepts and procedures inherent in machine repair 
technology. Without such knowledge, attempted repairs or service to this model may render it unfit 
to use and/or unsafe. 

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. 
Modifications and significant changes in specifications or procedures will be forwarded to all Autho- 
rized Yamaha dealers and will, where applicable, appear in future editions of this manual. 



TECHNICAL PUBLICATIONS 

SERVICE DIVISION 

MOTORCYCLE GROUP 

YAMAHA MOTOR CO., LTD. 



PARTICULARLY IMPORTANT INFORMATION 

This material is distinguished by the following notation. 






The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED! 



AWARNING 



Failure to follow WARNING instructions could result in severe injury or death 
to the motorcycle operator, a bystander, or a person inspecting or repairing 
the machine. 



CAPTION: A CAUTION indicates special precautions that must be taken to avoid damage 

to the machine. 



NOTE: 



A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

CONTRACTION OF THIS MANUAL 

This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 



1st title (D : 
2nd title (D : 

3rd title ® : 



This is a chapter with its symbol on the upper right of each page. 

This title appears on the upper of each page on the left of the chapter 
symbol. (For the chapter "Periodic inspection and adjustment" the 3rd 
title appears.) 

This is a final title. 



MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The infor- 
mation has been compiled to provide the mechanic with an easy to read, handy reference that 
contains comprehensive explanations of all disassembly, repair, assembly, and inspections. 
A set of particularly important procedure (D is placed between a line of asterisks "*" with each 
procedure preceded by " • ". 

IMPORTANT FEATURES 

• Data and a special tool are framed in a box preceded by a relevant symbol (D . 

• An encircled numeral © indicates a part name, and an encircled alphabetical letter data or an 
alignment mark (J) , the others being indicated by an alphabetical letter in a box ® . 

• A condition of a faulty component will precede an arrow symbol and the course of action re- 
quired the symbol (9). 



EXPLODED DIAGRAM 

Each chapter provides exploded diagrams before each disassembly section for ease in identif- 
ying correct disassembly and assembly procedures. 



®- 





f 




Werpeee 


measurement and tsaurfece- 






• Attach 


*ir»ighr edge © and a thick ne- 


M BffJBI 


® on the cylinder head. 


* Measure the warpefie 


• If the w 


rpafl* i* out of Specification, >•- 




lie cylinder head. 


* Place * 400 -- 600 grit wet ssndpaper on 


the turf 


ice plat*, and resurrect the head 




sure-eight sanding pattern. 






Retell the head several times to avoid re- 


move* «K 


much material from ons side. 




V 





FRONT FORK CHAS <£j® 




© 



GEN 
INFO 


<fr$ 


SPEC 


# 


® 


® 


INSP 


F3 


ENG 




ADJ 


© 


© 


COOL 


56 


CARB 


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® 



© 




© 



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DRIV 


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CHAS 


4* 


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® 


ELEC 


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• 


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Aft 




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* 


l> 




® 


% 


I 





® 




® 






I 



J 



® 



I 



© 



^^bk f^^c r^Si*. 



ILLUSTRATED SYMBOLS 
(Refer to the illustration) 

Illustrated symbols (T) to © are designed as 

thumb tabs to indicate the chapter's number and 

content. 

© General information 

(2) Specifications 

® Periodic inspection and adjustment 

(4) Engine 

(5) Cooling system 
(D Carburetion 

(7) Drive train 

® Chassis 

(D Electrical 

© Troubleshooting 



Illustrated symbols © to © are used to identify 

the specifications appearing in the text. 

© Filling fluid 

© Lubricant 

© Special tool 

© Tightening 

© Wear limit, clearance 

© Engine speed 

© fi, V, A 



Illustrated symbols @ to © in the exploded dia- 
gram indicate grade of lubricant and location of 
lubrication point. 

© Appply locking agent (LOCTITE®) 

© Apply engine oil 

® Apply gear oil 

(£j) Apply molybdenum disulfide oil 

© Apply wheel bearing grease 

© Apply lightweight lithium-soap base grease 

© Apply molybdenum disulfide grease 



INDEX 


GENERAL INFORMATION 


GEN Id 
INFO ■ ■ 




SPECIFICATIONS 


?? 

El 

spec|£4 




PERIODIC INSPECTION 
AND ADJUSTMENT 


INSPEp] 
ADJ M 




ENGINE OVERHAUL 


mi 

eng|^J 




CARBURETION 


4 

CARB0 




CHASSIS 


&6 

CHASpj 




ELECTRICAL 

— — - 


urn A 



TROUBLESHOOTING 



TRBL 
SHTG 



n 



CONTENTS 



CHAPTER 1. 
GENERAL INFORMATION 

MACHINE IDENTIFICATION M 

VEHICLE IDENTIFICATION NUMBER 1-1 

ENGINE SERIAL NUMBER 1-1 

IMPORTANT INFORMATION 1-2 

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2 

ALL REPLACEMENT PARTS 1-3 

GASKETS, OIL SEALS, AND O-RINGS 1-3 

LOCK WASHERS/PLATES AND COTTER PINS 1-3 

BEARINGS AND OIL SEALS 1-3 

CIRCLIPS 1-4 

SPECIAL TOOLS 1" 4 

FOR TUNE-UP 1-4 

FOR ENGINE SERVICE 1-5 

FOR CHASSIS SERVICE 1-7 

FOR ELECTRICAL COMPONENTS 1-8 

CHAPTER 2. 
SPECIFICATIONS 

GENERAL SPECIFICATIONS 2-1 

MAINTENANCE SPECIFICATIONS 2-4 

ENGINE 2-4 

CHASSIS 2-10 

ELECTRICAL 2-14 

GENERAL TORQUE SPECIFICATIONS 2-16 

DEFINITION OF UNITS 2 16 

LUBRICATION DIAGRAM 2-17 

CABLE ROUTING 2-19 



&% 



GEN 
INFO 




fif 



SPEC 




TNSF 



ADJ 



H 






ENG 



D 



4 



CARB 






^3* 



CHAS 






ELEC 




TRBL 
SHTG 






CHAPTER 3. 
PERIODIC INSPECTION AND ADJUSTMENT 

INTRODUCTION 3-1 

PERIODIC MAINTENANCE/LUBRICATION 3-1 

ENGINE 3-2 

VALVE CLEARANCE ADJUSTMENT 3-2 

SPARK PLUG INSPECTION 3-5 

CRANKCASE VENTILATION SYSTEM 3-7 

FUEL LINE 3-7 

INTAKE MANIFOLD 3-7 

EXHAUST SYSTEM 3-7 

IDLING SPEED ADJUSTMENT 3-8 

TIMING CHAIN ADJUSTMENT 3-9 

ENGINE OIL LEVEL INSPECTION 3-9 

ENGINE OIL REPLACEMENT 3-10 

CLUTCH ADJUSTMENT 3-13 

IGNITION TIMING CHECK 3-13 

COMPRESSION PRESSURE MEASUREMENT 3-14 

AIR FILTER CLEANING 3-16 

THROTTLE CABLE ADJUSTMENT 3-19 

SPEED LIMITER ADJUSTMENT 3-21 

CHASSIS 3-22 

BRAKE PAD INSPECTION 3-22 

BRAKE FLUID LEVEL INSPECTION 3-22 

FRONT BRAKE ADJUSTMENT 3-23 

REAR BRAKE ADJUSTMENT 3-24 

PARKING BRAKE ADJUSTMENT 3-26 

AIR BLEEDING 3-27 

DRIVE CHAIN SLACK ADJUSTMENT 3-28 

DRIVE CHAIN LUBRICATION 3-30 

FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 3-30 

BRAKE AND CHANGE PEDAL/BRAKE AND 

CLUTCH LEVERS LUBRICATION 3-33 

CABLE INSPECTION AND LUBRICATION 3-33 

STEERING AND SUSPENSION LUBRICATION 3-34 

WHEEL BEARINGS 3-34 

STEERING SYSTEM 3-34 

TOE-IN ADJUSTMENT 3-35 

TIRE INSPECTION 3-36 

WHEEL INSPECTION 3-39 

ELECTRICAL 3-39 

BATTERY INSPECTION 3-39 

FUSE INSPECTION 3-41 

HEADLIGHT BEAM ADJUSTMENT 3-43 

HEADLIGHT BULB REPLACEMENT .3-43 



CHAPTER 4. 
ENGINE OVERHAUL 



ENGINE REMOVAL 4-1 

ENGINE OIL 4-1 

SEAT, HEADLIGHT UNIT AND FUEL TANK .4-1 

CARBURETOR 4-1 

CLUTCH CABLE 4-2 

EXHAUST PIPE AND MUFFLER 4-2 

DRIVE SELECT LEVER AND CRANKCASE VENTILATION HOSE 4-3 

DRIVE CHAIN SPROCKET 4-3 

FOOTRESTS 4-3 

LEADS .4-4 

ENGINE REMOVAL 4-5 

ENGINE DISASSEMBLY 4-6 

DECOMPRESSION CAM, CAM CHAIN SPROCKET AND 

CYLINDER HEAD 4-6 

CYLINDER AND PISTON 4-8 

LEFT CRANKCASE COVER AND CDI MAGNETO 4-9 

CAM CHAIN AND STARTER MOTOR 4-11 

OIL FILTER AND NEUTRAL SWITCH 4-12 

RIGHT CRANKCASE COVER 4-12 

CLUTCH 4-13 

PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 4-14 

OIL PUMP .4-14 

SHIFT SHAFT 4-15 

OIL PIPE • -4-15 

CRANKCASE 4-15 

BEARINGS AND OIL SEALS .4-19 

CRANKSHAFT/ROCKER ARMS/VALVES 4-20 

INSPECTION AND REPAIR 4-22 

CYLINDER HEAD. - 4-22 

VALVE SEAT 4-23 

VALVE/VALVE GUIDE 4-26 

CAMSHAFT 4-27 

ROCKER ARM/ROCKER ARM SHAFT .4-28 

VALVE SPRING 4-29 

TIMING CHAIN/CHAIN GUIDE/SPROCKET 4-29 

CYLINDER/PISTON 4-30 

PISTON RING 4-32 

PISTON PIN - 4-33 

CRANKSHAFT/CONNECTING ROD 4-34 

ELECTRIC STARTER DRIVES 4-34 

PRIMARY DRIVE 4-35 

CLUTCH 4-36 

OIL PUMP 4-38 

SHIFTER .4-38 

TRANSMISSION .4-39 



&Q 



GEN 
INFO 





<m6 



CHAS 



m 



ELEC 




TRBL 
SHTG 



H 



BALANCER DRIVE GEAR 4-40 

CRANKCASE 4-40 

BEARING AND OIL SEALS 4-41 

ENGINE ASSEMBLY AND ADJUSTMENT .... 4-42 

CAMSHAFT/ROCKER ARMS/VALVES 4-42 

TRANSMISSION/BALANCER/CRANKSHAFT 4-45 

CRANKCASE 4-51 

OIL PIPE 4-52 

SHIFT SHAFT 4-52 

OIL PUMP 4-53 

BALANCER DRIVEN GEAR AND PRIMARY DRIVE GEAR 4-53 

CLUTCH 4-54 

RIGHT CRANKCASE COVER 4-57 

NEUTRAL SWITCH AND OIL FILTER 4-57 

STARTER MOTOR AND CAM CHAIN 4-58 

CDI MAGNETO AND LEFT CRANKCASE 4-58 

CYLINDER HEAD/CYLINDER/PISTON 4-60 

REMOUNTING ENGINE 4-67 



CHAPTER 5. 
CARBURETION 

CARBURETOR 5-1 

SECTION VIEW 5-2 

REMOVAL 5-3 

DISASSEMBLY 5-4 

INSPECTION 5-6 

ASSEMBLY 5-7 

INSTALLATION 5-8 

FLOAT HEIGHT ADJUSTMENT 5-9 

FUEL LEVEL ADJUSTMENT 5-10 

WIRE CYLINDER 5-11 

REMOVAL, 5-11 

INSPECTION 5-11 

INSTALLATION 5-12 



CHAPTER 6. 
CHASSIS 

FRONT WHEEL AND WHEEL HUB 6-1 

REMOVAL 6-2 

INSPECTION 6-3 

INSTALLATION 6-4 



REAR WHEEL AND WHEEL HUB 6-6 

REMOVAL 6-7 

INSPECTION 6-8 

INSTALLATION 6-9 

FRONT BRAKE 6-12 

BRAKE PAD REPLACEMENT 6-14 

CALIPER 6-15 

AIR BLEEDING 6-18 

MASTER CYLINDER DISASSEMBLY 6-19 

BRAKE DISC 6-20 

REAR BRAKE 6-22 

BRAKE PAD REPLACEMENT , 6-23 

CALIPER DISASSEMBLY 6-24 

MASTER CYLINDER DISASSEMBLY 6-26 

INSPECTION AND REPAIR 6-27 

ASSEMBLY 6-27 

AIR BLEEDING 6-29 

FRONT SUSPENSION 6-30 

REMOVAL 6-31 

INSPECTION , 6-32 

INSTALLATION , 6-33 

STEERING SYSTEM .....6-34 

REMOVAL 6-35 

INSPECTION 6-36 

INSTALLATION 6-37 

REAR SHOCK ABSORBER AND SWINGARM 6-39 

HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 6-40 

DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 6-40 

REMOVING THE REAR SHOCK ABSORBER 6-41 

CHECKING THE REAR SHOCK ABSORBER 6-41 

CHECKING THE RELAY ARM AND CONNECTING ARM 6-41 

INSTALLING THE REAR SHOCK ABSORBER 6-42 

REMOVING THE SWINGARM 6-42 

CHECKING THE SWINGARM.... 6-42 

CHECKING THE DRIVE CHAIN 6-43 

INSTALLING THE SWINGARM 6-44 

CHAPTER 7. 
ELECTRICAL 

YFA350XA CIRCUIT DIAGRAM 7-1 

ELECTRICAL COMPONENTS 7-3 




m 



INSP 
ADJ 





ICHASh § 




+r 



ELEC 




TRBL 
ISHTG 




CHECKING OF SWITCHES 7-4 

SWITCH CONNECTION AS SHOWN IN MANUAL 7-4 

CHECKING SWITCH FOR TERMINAL CONNECTION 7-4 

CHECKING OF BULBS(FOR HEADLIGHT, TAIL/BRAKE LIGHT, 

FLASHER LIGHT, METER LIGHT, ETC.) 7-7 

KIND OF BULBS 7.7 

CHECKING BULB CONDITION Z.../7-7 

ELECTRICAL STARTING SYSTEM , 7.9 

CIRCUIT DIAGRAM 7.9 

STARTING CIRCUIT OPERATION ."."!!!.7-1 1 

TROUBLESHOOTING " 7 _ 12 

CHARGING SYSTEM 7 _21 

CIRCUIT DIAGRAM , Z.7-21 

TROUBLESHOOTING 7.23 

IGNITION SYSTEM , .7.27 

CIRCUIT DIAGRAM ".'.'.'.'.'.".7-27 

TROUBLESHOOTING IZ/7-29 

LIGHTING SYSTEM 7.35 

CIRCUIT DIAGRAM , ..Z*7-35 

TROUBLESHOOTING IZ.7-39 

SIGNAL SYSTEM , 7 . 41 

CIRCUIT DIAGRAM , IZj-41 

TROUBLESHOOTING ^ 7 _43 

SIGNAL SYSTEM CHECK '"7.45 

CHAPTER 8. 
TROUBLESHOOTING 

STARTING FAILURE/HARD STARTING 8-1 

POOR IDLE SPEED PERFORMANCE 8-3 

POOR MEDIUM AND HIGH SPEED PERFORMANCE 8-3 

FAULTY GEAR SHIFTING , 8 -4 

CLUTCH SLIPPING/DRAGGING 8 4 

OVERHEATING 8-5 

FAULTY BRAKE 8 . 5 

SHOCK ABSORBER MALFUNCTION 8-6 

INSTABLE HANDLING 8-6 

FAULTY LIGHTING SYSTEM , 8 -6 

YFM350XA WIRING DIAGRAM 



MACHINE IDENTIFICATION 



GEN 
INFO 



6^S 





GENERAL 
INFORMATION 

MACHINE IDENTIFICATION 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number (D is stam- 
ped into the left side of frame. 




Starting serial number: 
JY43GDW0#LC051101 



NOTE: 

The vehicle identification number is used to 
identify your machine and may be used to re- 
gister your machine with the licensing au- 
thority in your state. 



ENGINE SERIAL NUMBER 

The engine serial number (D is stamped into 
the right side the engine. 



Starting serial number: 
3GD-051101 



NOTE: 

• The first three digits of these numbers are 
for model identifications; the remaining 
digits are the unit production number. 

• Designs and specifications are subject to 
change without notice. 



1-1 



IMPORTANT INFORMATION 



GEN 
INFO 


0^5 



WB212O01 

IMPORTANT INFORMATION 

PREPARATION FOR REMOVAL AND DISAS- 
SEMBLY 

1 . Remove all dirt, mud, dust, and foreign ma- 
terial before removing and disassembling. 



2. Use proper tools and cleaning equipment. 
Refer to "SPECIAL TOOL". 



3. When disassembling the machine keep 
mated parts together. This includes gears, 
cylinders, pistons, and other mated parts 
that have been "mated" through normal 
wear. Mated parts must be reused as an 
assembly or replaced. 



4. During the machine disassembly, clean all 
parts and place them in trays in the order 
of disassembly. This will speed up assemb- 
ly time and help assure that all parts are 
correctly reinstalled. 



5. Keep away from fire. 



1-2 



IMPORTANT INFORMATION 



GEN 
INFO 


o*d 



WB212002 

ALL REPLACEMENT PARTS 

1. We recommend to use Yamaha genuine 
parts for all replacements. Use oil and/or 
grease recommended by Yamaha for asse- 
mbly and adjustment. 



WB212003 

GASKETS, OIL SEALS, AND O-RINGS 

1 . All gaskets, seals and O-rings should be re- 
placed when an engine is overhauled.AII ga- 
skets surfaces, oil seal lips and O-rings 
must be cleaned. 




7777777777 1 





300-002 



2. Properly oil all mating parts and bearing 
during reassembly. Apply grease to the oil 
seal lips. 

WB212004 

LOCK WASHERS/PLATES AND COTTER 
PINS 

1. All lock washers/plates (D and cotter 
pins must be replaced when they are remo- 
ved. Lock tab(s) should be bent along the 
bolt or nut flat(s) after the bolt or nut has 
been properly tightened. 



WB212005 

BEARINGS AND OIL SEALS 

1. Install the bearing(s) and oil seal(s) with 
their manufacturer's marks or numbers 
facing outward.lln other words, the stam- 
ped letters must be on the side exposed 
to view.) When installing oil seal(s), apply 
a light coating of light-weight lithium base 
grease to the seal lip(s). Oil the bearings li- 
berally when installing. 

(D Oil seal 



Do not use compressed air to spin the 
bearings dry. This causes damage to the 
bearing surfaces. 

(D Bearing 



1-3 




GEN 
INFO 


^5 



SPECIAL TOOLS 



WB212006 

CIRCLIPS 

1. All circlips should be inspected carefully 
before reassembly. Always replace piston 
pin clips after one use. Replace distorted 
circlips. When installing a circlip (D , make 
sure that the sharp edged corner (2) is po- 
sitioned opposite to the thrust (3) it recei- 
ves. See the sectional view. 

® Shaft 

WB313001 

SPECIAL TOOLS 

The prepare special tools are necessary for 
complete and accurate tune-up and assemb- 
ly. Using the correct special tool will help pre- 
vent damage caused by the use of improper 
tools or improvised techniques. 




FOR TUNE UP 

1 . Inductive tachometer 
P/N.YU-8036-A 



This tool is needed for detecting engine rpm. 

2. Inductive timing light 
P/N. YM-33277-A 



This tool is necessary for checking ignition 
timing. 

3. Compression gauge 
P/N. YU-33223 



This tool is used to measure the engine com- 
pression. 



1-4 




SPECIAL TOOLS 





o 


t 
r 

r 

t 

h* 





Fuel level gauge 
P/N.YM-01312-A 



GEN 
INFO 


^8 



This gauge is used to measure the fuel level 
in the float chamber. 

FOR ENGINE SERVICE 

1 . Piston pin puller 
P/N.YU-01304 




This tool is used to remove the piston pin. 

2. Rotor holder 
P/N.YU-01235 



This tool is used to hold the clutch when re- 
moving or installing the clutch boss locknut. 

3. Crankcase separator 

P/N.YU-01135 ® 

Adapter 
P/N.YM-1382 (D 



4. Valve spring compressor 
P/N.YM-04019 



This tools are used to remove and install the 
valve assembles. 



1-5 



GEN 
INFO 


0*6 




SPECIAL TOOLS 



5. Valve guide remover {7.0 mm) 

P/N.YM-01227 (D 

Valve guide reamer (7.0 mm) 

P/N.YM-01225 <D 

Valve guide installer (7.0 mm) 
P/N.YM-4017 ® 

These tools are used to remove, install and 
rebore the valve guide. 

6. Valve seat cutter 
P/N.YM-91043 



This tool is used to adjust the valve clearan- 
ce. 

7. Quick gasket® 

P/N.ACC-1 1001-05-01 



This sealant (bond) is used for crankcase 
mating surface, etc. 

8. Slide hammer set 
P/N.YU-01083 



These tools are used when removing the 
rocker arm shaft. 

9.Valve adjusting tool 
P/N. YM-08035 



This tool is used for adjusting the valve 
clearance. 



1-6 



SPECIAL TOOLS 



GEN 
INFO 


o^s 




lO.Crankshaft installer set 
P/N. YU-90050 



This tool is used for installing the crankshaft. 

1 1. Adapter 

P/N.YM-1383 



This tool is used for installing the crankshaft. 

12.Spacer 

P/N.YM-91044 



This tool is used for installing the crankshaft. 

13. Fly wheel puller 
P/N.YM-01404 



This tool used for removing the CDI rotor. 

FOR CHASSIS SERVICE 

1 . Rear axle nut wrench 
P/N.YM-37132 



This tool is used to loosen and tighten the 
nut(Rear axle). 



1-7 



SPECIAL TOOLS 



GEN 
INFO 


6*5 




2. Ball joint wrench 
P/N.YM-01405 



This tool is used to loosen and tighten the su- 
spension ball joint. 



3. Ring nut wrench 
P/N.YU-01268... 
P/N.YU-33975... 



(D 

(D 



This tool is used to loosen and tighten the 
steering ring nut. 

FOR ELECTRICAL COMPONENTS 

1 . Dynamic spark tester 
P/N. YM-34487 



This instrument is necessary for checking 
the ignition system components. 

2. Pocket tester 
P/N.YU-03112 



This tester is invaluable for checking the ele- 
ctrical system. 



1-8 



GENERAL SPECIFICATIONS 



SPEC 


p? 



SPECIFICATIONS 



GENERAL SPECIFICATIONS 



Model 


YFM350XA 


Model Code Number 


3GD5 


Vehicle Identification Number 


JY43GDW0*LC051101 


Engine Starting Number 


3GD-051101 


Dimensions: 
Overall Length 
Overall Width 
Overall Height 
Seat Height 
Wheelbase 
Minimum Ground Clearance 


1,840 mm (72.4 in) 
1,080 mm (42.5 in) 
1,080 mm (42.5 in) 

765 mm (30.1 in) 
1,200 mm (47.2 in) 

125 mm (4.92 in) 


Basic Weight: 
With Oil and Full Fuel Tank 


191 kg (421 lb) 


Minimum Turning Radius 


3,500 mm (138 in) 


Engine: 
Engine Type 
Cylinder Arrangement 
Displacement 
Bore x Stroke 
Compression Ratio 
Compression Pressure 
Starting System 


4-stroke, gasoline, SOHC, 

Single cylinder 

348 cm 3 (21.2 cu.in) 

83x64.5 mm (3.27x2.54 in) 

9.2x1 

834 kPa (8.5 kg/cm 2 , 121 psi) 

Electric starter 


Lubrication System 


Wet sump 


Oil Type or Grade 
Engine Oil 


SAE 10W40 type SE motor oil 


Oil Capacity: 
Engine Oil 

Periodic Oil Change 

With Oil Filter Replacement 

Total Amount 


2.4 L (2.11 Impqt, 2.53 US qt) 

2.5 L (2.20 Imp qt, 2.64 US qt) 
3.2 L (2.82 Imp qt, 3.38 US qt) 


Air Filter 


Wet type element 



2-1 



GENERAL SPECIFICATIONS 



SPEC 


PI 



Model 


YFM350XA 


Fuel: 
Type 

Tank Capacity 
Reserve Amount 


Regular gasoline 

9.5 L (2.1 Imp gal, 2.5 US gal) 

1.9 L (0.4 Imp gal, 0.5 US gal) 


Carburetor: 
Type/Manufacturer 


BTM36SH/MIKUNI 


Spark Plug: 
Type/Manufacturer 
Gap 


D8EA (NGK), X24ES-U (ND) 
0.6-0.7 mm (0.024-0.028 in) 


Clutch Type 


Wet, multiple-disc 


Transmission: 
Primary Reduction System 
Primary Reduction Ratio 
Secondary Reduction System 
Secondary Reduction Ratio 
Transmission Type 
Operation 
Gear Ratio 1st 

2nd 

3rd 

4th 

5th 

6th 

Reverse 


Spar gear 

76/24 (3.167) 

Chain drive 

40/13 (3.077) 

Constant mesh, 6-speed forward, 1 -speed reverse 

Left foot operation 

36/16x20/27x29/18 (2.685) 

33/20x20/27x29/18 (1.969) 

29/23x20/27x29/18 (1.505) 

27/26x20/27x29/18 (1.239) 

25/28x20/27x29/18 (1.066) 

23/29x20/27x29/18 (0.947) 

33/16x33/10 (6.806) 


Chassis: 
Frame Type 
Caster Angle 
Trail 


Steel Tube Frame 

7° 

30 mm (1.2 in) 


Tire: 
Type . 
Size (F) 
Size (R) 


Tubeless 

AT21x7-10 
AT22X10-9 


Basic Weight: 
With Oil and Full Fuel Tank 


191 kg (421 lb) 


Cold Tire Pressure 


Front 


Rear 


30 kPa 

(0.3 kg/cm 2 

4.3 psi) 


25 kPa 

(0.25 kg/cm 2 

3.6 psi) 


Brake: 

Front Brake Type 
Operation 
Rear Brake Type 
Operation 


Dual disc brake 
Right hand operation 
Single Disc brake 
Right foot operation 



2-2 



GENERAL SPECIFICATIONS 



SPEC 


Pf 



Model 


YFM350XA 


Suspension: 
Front Suspension 
Rear Suspension 


Double Wishbone 
Swingarm (Link Suspension) 


Shock Absorber: 
Front Shock Absorber 
Rear Shock Absorber 


Coil spring/Oil damper 
Coil spring, Gas/Oil damper 


Wheel Travel: 
Front Wheel Travel 
Rear Wheel Travel 


200 mm (7.9 in) 
200 mm (7.9 in) 


Electrical: 
Ignition System 
Generator System 
Battery Capacity 
Battery Type 


C.D.I. Magneto 
Flywheel magneto 
12V 12AH 
GM12CZ-4A 


Headlight Type 


Bulb Type 


Bulb Wattage/ Quantity: 
Headlight 
Taillight 
Neutral Light 
Reverse Light 


25W/25Wx2 
3.8Wx1 
3.4Wx1 
3.4Wx1 



2-3 



MAINTENANCE SPECIFICATIONS 



SPEC 


PI 



MAINTENANCE SPECIFICATIONS 



ENGINE 



Model 



Cylinder Head: 
Warp Limit 




Cylinder: 
Bore Size 
Taper Limit 



Camshaft: 
Drive Method 
Cam Dimensions 
Intake 



Exhaust 




"A" 
"B" 
"C" 



"A" 
"B" 
"C" 



YFM350XA 



<0.03 mm (0.0012 in)> 
* Lines indicate straightedge 
measurement 



82.97-83.02 mm (3.267-3.269 in) 
<0.05 mm (0.002 in)> 



Camshaft Runout Limit 




Chain (Left) 

40.62-40.72 mm (1.599-1.603 in) 
32.18-32.28 mm (1.267-1.271 in) 
8.67 mm (0.341 in) 



40.62-40.72 mm (1.599-1.603 in] 
32.18-32.28 mm (1.267-1.271 in) 
8.67 mm (0.341 in) 



< 0.03 mm (0.001 in}> 



Cam Chain Type/ 
Nomber of Links 
Cam Chain Adjustment Method 



Rocker arm/ Rocker arm shaft: 
Bearing inside diameter 
Shaft outside diameter 
Arm-to-shaft clearance 



Valve, Valve Seat, Valve Guide: 
Valve Clearance (Cold) 



IN. 
EX. 



BF05M/90 Links 
Automatic 



12.00-12.02 mm (0.472-0.473 in) 
11.98-11.99 mm (0.472 in) 
0.009-0.037 mm (0.0004-0.0015 in) 



0.06-0.10 mm 
(0.00236-0.00394 in) 
0.16-0.20 mm 
(0.00630-0.00787 in) 



2-4 



MAINTENANCE SPECIFICATIONS 



SPEC 


n 



Model 



Valve Dimensions: 



£ 



3 



Head Dia. 

"A" 




_» Face Width 



"A" Head Dia. 

"B" Face Width 

"C" Seat Width 

"D" Margin Thickness Limit 

Stem Outside Diameter 

Guide Inside Diameter 

< Limit > 

< Limit > 
Stem-to-guide 

Clearance 

< Limit > 



IN. 
EX. 
IN. 
EX. 
IN. 
EX. 

IN. 
EX. 
IN. 
EX. 
IN. 

EX. 

IN. 

EX. 
IN. 
EX. 



YFM350XA 




i», 



Seat Width 



Margin Thickness 



39.9-40.1 mm (1.571-1.579 in) 

33.9-34.1 mm (1.335-1.343 in) 

2.26 mm (0.09 in) 

2.26 mm (0.09 in) 

1.2-1.4 mm (0.047-0.055 in) 

1.2-1.4 mm (0.047-0.055 in) 

1.0-1.4 mm (0.039-0.0551 in) 
0.8-1.2 mm (0.0315-0.0472 in) 
6.975-6.990 mm (0.2746-0.2752 in) 
6.955-6.970 mm (0.2738-0.2744 in) 
7.000-7.012 mm (0.2756-0.2761 in) 
<7.5 mm (0.295 in)> 
7.000-7.012 mm (0.2756-0.2761 in) 
<7.5 mm (0.295 in)> 
0.010-0.037 mm (0.0004-0.0015 in) 



Stem Runout Limit 




TT77 

Valve Seat Width Standard 



IN. EX. 



0.030-0.057 mm (0.00118 
0.1 mm (0.004 in) 
0.1 mm (0.004 in) 



0.00224 in) 



<0.01 mm (0.0004 in)> 



1.1 ±0.1 mm (0.043 ±0.004 in) 



2-5 



MAINTENANCE SPECIFICATIONS 



Model 



Valve Spring: 
Free Length 
Inner Spring 

Outer Spring 

Set Length (Valve Closed) 
Inner Spring 

Outer Spring 



IN. 
EX. 
IN. 
EX. 

IN. 
EX. 
IN. 
EX. 



Tilt Limit* 
Inner Spring 
Outer Spring 



IN.&EX. 
IN.&EX. 




\\\\\\\\\\\\^\\\\\\\\ 



Direction of Winding (Top view) 



Piston: 

Piston Size "D" 
Measuring Point "H" 

Piston Clearance 

Oversize 2nd 

4th 
Piston off-set 
Piston off-set Direction 
Inside Diameter (Piston pin bore) 
Outside Diameter {Piston pin) 




SPEC 


Pt 



YFM350XA 



39.9 mm (1.571 in) 
39.9 mm (1.571 in) 
43.27 mm (0.587 in) 
43.27 mm (0.587 in) 

33.6 mm (1.323 in) 
33.6 mm (1.323 in) 
36.6 mm (1.441 in) 
36.6 mm (1.441 in) 



2.5° or 1.6 mm (0.0630 in) 
2.5° or 1.6 mm (0.0630 in) 



Inner Spring 



Left 




Outer Spring 



Right 




82.040-82.050 mm (3.230 in) 

5.5 mm (0.217 in) 

(From bottom line of piston skirts) 

0.040-0.060 mm 

(0.00157-0.00236 in) 

83.5 mm (3.287 in) 

84.0 mm (3.307 in) 

0.5 mm (0.02 in) 

Intake side 

19.004-19.015 mm (0.75 in) 

18.990-18.995 mm (0.75 in) 



2-6 



MAINTENANCE SPECIFICATIONS 



SPEC 


Pf 



Model 



YFM350XA 



Piston Ring: 
Sectional Sketch 
Top Ring 



2nd Ring 
Oil Ring 




B 

T 

B 

T 
B 

T 



Barrel 

1.2 mm (0.047 in) 

3.3 mm (0.130 in) 
Taper 

1.5 mm (0.059 in) 

3.4 mm (0.134 in) 
2.8 mm (0.110 in) 

2.5 mm (0.098 in) 



End Gap (Installed) 



Side Clearance 



Top Ring 
2nd Ring 
Oil Ring 
Top Ring 
2nd Ring 



0.20-0.40 mm (0.00787-0.0157 in) 
0.20-0.40 mm (0.00787-0.0157 in) 
0.30-0.90 mm (0.012-0.035 in) 
0.04-0.08 mm (0.00157-0.00315 in) 
0.03-0.07 mm (0.00118-0.00276 in) 



Crankshaft: 







_D 



^ 



Crank Width "A" 

Big End Side Clearance "B" 

Runout Limit "C" 

Small End Free Play Limit "F" 



58.95-59.00 (2.321-2.323 in) 
0.35-0.85 mm (0.014-0.0335 in) 
<0.06 mm (0.00236 in)> 
0.8-1.0 mm (0.0315-0.0394 in) 



Balancer Drive Method 



Gear 



Clutch: 

Friction Plate Thickness/ 
Quantity 
Wear Limit 
Clutch Plate Thickness/Quantity 

Warp Limit 
Clutch Spring Free 

Length/Quantity 
Clutch Spring Minimum Free 
Length 
Clutch Release Method 



2.94-3.06 mm 

(0.116-0.120 in)/7 

<2.8 mm (0.110 in)> 

1.5-1.7 mm (0.059-0.066 in)/4 

1.9-2.1 mm (0.0748-0.0827 in)/2 

<0.2 mm (0.00787 in)> 

47.8 mm (1.882 in)/5 
46.5 mm (1.831 in) 

Outer push (Rack & Pinon) 



2-7 



MAINTENANCE SPECIFICATIONS 



spec py 



Model 


YFM350XA 


Decompression Device: 








Type 




Manual 




Air Filter Oil Grade (Oiled Filter) 


Foam-Air-Filter Oil or 








SAE 10W30 SE motor oil 




Carburetor: 








Type/Manufacturer/Quantity 


BTM36SH/MIKUNI/1 




LD. Mark 




2XK-00 




Main jet 


(M.J.) 


#145 




Main Air Jet 


(M.A.J.) 


00.6 




Jet Needle-clip 








Position 


(J.N.) 


5J18-3 




Needle Jet 


(M.M.) 


0-6 




Pilot Jet 


(P.J.) 


#42.5 




Pilot Ait Jet 


(P.A.J!) 


^1.0 






(P.A.J 2 ) 


00.7 




Pilot Screw {turns out) 


(P.S.) 


2 




Valve Seat 


(V.S.) 


02.5 




Starter Jet 


(G.S.) 


#62.5 




Fuel Level 


(F.L) 


3-4 mm (0.12-0.16 in) 




Float Height 




11.4-13.4 mm (0.45-0.53 in) 




Engine Idling Speed 




1,450-1,550 r/min 




Vacuum Pressure at Idling 


Speed 


33.3 kPa (250 mmHg, 9.84 inHg) 




Lubrication System: 








Oil Filter Type 




Wire mesh 




Oil Pump Type 




Trochoid pump 




Tip Clearance 




0.15 mm (0.006 in) 




Housing and Outer Rotor 








Clearance 




0.04-0.09 mm (0.002-0.004 in) 




Side Clearance 




0.04-0.09 mm (0.002-0.004 in) 





2-8 



MAINTENANCE SPECIFICATIONS 



SPEC 


91 



TIGHTENING TORQUE: 


Parts to be tightened 


Parts name 


Thread 
Size 


Q'ty 


Tightening Torque 


Remarks 


Nm 


m»kg 


ft* lb 


Cylinder head 


Flange bolt 


M10 


4 


40 


4.0 


29.0 


1 




Hex bolt 


M8 


2 


20 


2.0 


14.0 


191 


Cylinder body 


Hex bolt 


M6 


1 


10 


1.0 


7.2 


Cylinder head cover (Valve) 


Hex bolt 


M6 


5 


10 


1.0 


7.2 




(Sprocket) 


Pan head screw 


M6 


2 


10 


1.0 


7.2 




Camshaft bearing plate 


Hex bolt 


M6 


2 


8 


0.8 


5.8 


Use lock 
washer. 


Oil checking bolt 


Bolt 


M6 


1 


7 


0.7 


5.1 




Spark plug 


— 


M12 


1 


17.5 


1.75 


12.5 




Balancer shaft 


Hex nut 


M16x1.0 


1 


60 


6.0 


43.0 


Use lock 
washer. 


Flywheel magneto 


Bolt 


M10X1.25 


1 


50 


5.0 


36.0 




Valve clearance (Locknut) 


Hex nut 


M7 


2 


20 


2.0 


14.0 




Cam sprocket 


Bolt 


M10 


1 


60 


6.0 


43.0 




Intake side chain guide 


Bolt 


M6 


2 


10 


1.0 


7.2 




Oil pump 


Pan head screw 


M6 


4 


7 


0.7 


5.1 




Drain plug 


— 


M35 


1 


32 


3.2 


23 




Filter cover 


Hex bolt 


M6 


3 


10 


1.0 


7.2 




Carburetor 


Nut 


M8 


2 


16 


1.6 


11.0 




Carburetor clamp hose 


Pan head screw 


M5 


1 


2 


0.2 


1.4 




Muffler mount 


Flange bolt 


M8 


3 


27 


2.7 


19.0 




Exhaust pipe 


Nut 


M6 


2 


12 


1.2 


8.7 


h 


Exhaust pipe protector 


Pan head screw 


M6 


4 


8 


0.8 


5.8 


Crankcase 


Flange bolt 


M6 


16 


10 


1.0 


7.2 




Case cover 


Flange bolt 


M6 


11 


10 


1.0 


7.2 




Clutch spring 


Hex bolt 


M6 


5 


8 


0.8 


7.2 




Clutch boss 


Hex nut 


M16 


1 


80 


8.0 


43.0 




Primary drive gear 


Hex nut 


M16 


1 


80 


8.0 


36.0 




Drive sprocket 


Nut 


M20 


2 


75 


7.5 


7.2 




Shift pedal 


Hex bolt 


M6 


1 


10 


1.0 


7.2 




Cam chain tensioner (Body) 


Hex bolt 


M6 


2 


10 


1.0 


7.2 




(Blind) 


Bolt 


M12 


1 


38 


3.8 


27.0 




Muffler and Exhaust pipe 


Hex bolt 


M8 


1 


20 


2.0 


14.0 




Pulser coil 


Screw 


M5 


2 


5 


0.5 


5.1 




Source coil 


Screw 


M6 


3 


7 


0.7 


5.1 




Recoil starter 


Bolt 


M6 


4 


10 


1.0 


7.2 




Starter motor 


Bolt 


M6 


2 


10 


1.0 


7.2 




Neutral switch 


— 


M10 


1 


20 


2.0 


14.0 




Reverse switch 


— 


M10 


1 


20 


2.0 


14.0 




Stopper lever 


Bolt 


M6 


1 


14 


1.4 


10.0 




Reverse shift cam 
















stopper bolt 


Bolt 


M14 


1 


10 


1.0 


7.2 





2-9 



MAINTENANCE SPECIFICATIONS 



■ I 

SPEC pf 

I, I,-. 



CHASSIS 



Model 


YFM350XA 


Steering System: 




Lock to Lock Angle: 




Left 


40° 


Right 


40° 


Front Suspension: 




Shock Absorber Stroke 


90 mm (3.54 in) 


Shock Absorber Spring Free Length 


224.0 mm (8.82 in) 


Spring Rate (K1) 


39.2 N/mm (4.0 kg/mm, 224 lb/in) 


Stroke 


Zero- 109.5 mm (Zero -4.31 in) 


Optional spring 


No 


Rear Suspension: 




Shock Absorber Stroke 


88 mm (3.46 in) 


Shock Absorber Spring Free Length 


240.5 mm (9.47 in) 


Spring Rate (K1) 


53.9 N/mm (5.5 kg/mm, 308 lb/in) 


Stroke 


Zero- 108 mm (Zero -4.25 in) 


Enclosed Gas Pressure (Standard) 


1,176 kPa (12 kg/cm 2 , 170 psi) 


(Min) 


784 kPa (8 kg/cm 2 , 114 psi) 


(Max) 


1,569 kPa {16 kg/cm 2 , 227 psi) 


Swingarm: 




Free Play Limit: 




Side 


< 1.0 mm (0.04 in)> 


Wheel: 




Front Wheel Type 


Panel Wheel 


Rear Wheel Type 


Panel Wheel 


Front Rim Size/Material 


1Qx6/Aluminum 


Rear Rim Size/ Material 


9x8.25/Aluminum 


Rim Runout Limit: 




Vertical 


<2.0 mm (0.08 in)> 


Lateral 


<2.0 mm (0.08 in)> 


Front Disc Brake: 




Type 


Dual disc 


Disc Outside x Thickness 


161 x3.5 mm (6.34x0.138 in) 


Pad Thickness 


4.5 mm (0.177 in) 


< Limit > 


< 1.0 mm (0.039 in)> 


Rear Disc Brake: 




Type 


Single disc 


Disc Outside Diameter x Thickness 


245x3.5 mm (9.65x0.14 in) 


< Limit > 


<3.0 mm (0.12 in)> 


Pad Thickness 


4.5 mm (0.177 in) 


< Limit > 


< 1.0 mm (0.0394 in)> 



2-10 



MAINTENANCE SPECIFICATIONS 



SPEC 0f 



Model 


YFM350XA 


Brake Lever & Brake Pedal: 
Brake Lever Free Play 
Brake Pedal Position 
Brake Pedal Free Play 


4-8 mm (0.157-0.315 in) at lever end 
10 mm (0.4 in) 
8 mm (0.315 in) 


Drive Chain: 
Type/ Manufacturer 
Number of links 
Chain Free Play 


520V6/DAIDO 

98 links 

30-40 mm (1.18-1.57 in) 


Clutch lever Free Play: 


5-10 mm (0.20-0.39 in)/at lever end 



2-11 



MAINTENANCE SPECIFICATIONS 


; ! 


SPEC 


p? 




TIGHTENING TORQUE: 










Tightening Torque 




Parts to be tightened 


Parts name 


Thread Size 


Q'ty 




- Remarks 
















Nm 


m»kg 


ft-lb 




Steering Knuckles & Nut 


Nut 


M14x1.5 


2 


85 


8.5 


61 




Wheel Panel Nut 


Nut 


M10X1.25 


16 


45 


4.5 


32 




Bearing Holder & Frame 


Nut 


M42X1.0 


1 


40 


4.0 


29 




Steering Knuckle & Knuckle Arm 


Bolt 


M10x1.25 


4 


38 


3.8 


27 




Steering Knuckle & Brake Caliper 


Bolt 


M8X1.25 


4 


28 


2.8 


20 




Disc Brake & Front Hub 


Hex bolt 


M8x1.25 


4 


28 


2.8 


20 




Ball Joint & Steering Knuckle 


Nut 


M10x1.25 


4 


25 


2.5 


18 




Tie Rod Assembly & Knuckle Arm 


Nut 


M10X1.25 


4 


25 


2.5 


18 




Tie Rod Assembly & 


Nut 


M10x1.25 


2 


25 


2.5 


18 




Steering Shaft 
















Tie Rod Assembly Locknut 


Nut 


M1 Ox 1,25 


4 


30 


3.0 


22 




Steering Shaft & Frame 


Nut 


M10X1.25 


1 


30 


3.0 


22 




Steering Bearing & Frame 


Bolt 


M8x1.25 


2 


23 


2.3 


17 




Steering Shaft & Upper 


Bolt 


M8X1.25 


4 


20 


2.0 


14 




Handlebar Holder 
















Upper and Lower Arm & Frame 


Bolt 


M10X1.25 


4 


45 


4.5 


32 




Front Shock Absorber 


Bolt 


M10x1.25 


4 


45 


4.5 


32 




(Upper & Lower) 
















Upper Engine Stay & Frame 


Bolt 


M8X1.25 


4 


33 


3.3 


24 




Upper Engine Stay & Engine 


Bolt 


M8x1.25 


1 


33 


3.3 


24 




Frame & Engine 


Bolt 


M10x1.25 


3 


55 


5.5 


40 




Pivot Shaft 


Bolt 


M16X1.5 


1 


85 


8.5 


61 




Rear Shock Absorber 


Bolt 


M10X1.25 


2 


32 


3.2 


23 




(Upper & Lower) 
















Relay Arm & Frame 


Bolt 


M10X1.25 


1 


48 


4.8 


35 




Connecting Rod & Rear Arm 


Bolt 


M10X1.25 


1 


48 


4.8 


35 




Relay Arm & Connecting Rod 


Bolt 


M10X1.25 


1 


32 


3.2 


23 




Footrest & Frame 


Bolt 


M10x1.25 


4 


55 


5.5 


40 




Disc Brake & Bracket 


Bolt 


M8X1.25 


4 


28 


2.8 


20 




Brake Caliper & Rear Hub 


Bolt 


M8X1.25 


2 


23 


2.3 


17 




Wheel Panel & Wheel Shaft Collar 


Nut 


M10x1.25 


8 


45 


4.5 


32 




Rear Axle Ring Nut 


Nut 


M38x1.5 


2 


— 


— 


— 


SEE NOTE 


Rear Axle Nut 


Nut 


M14x1.5 


2 


120 


12.0 


85 




Rear Hub & Swingarm (Upper) 


Bolt 


M12X1.25 


2 


120 


12.0 


85 




Rear Hub & Swingarm (Lower) 


Bolt 


M10X1.25 


2 


60 


6.0 


43 




Brake Hose & Caliper, 


Bolt 


M10X1.25 


5 


27 


2.7 


19 




Master Cylinder 
















Rear Master Cylinder & Frame 


Bolt 


M8X1.25 


2 


20 


2.0 


14 




Front Bumper 


Bolt 


M8X1.25 


4 


23 


2.3 


17 




Rear Bumper 


Bolt 


M8X1.25 


4 


23 


2.3 


17 




Fuel Cock & Fuel Tank 


Screw 


M6x1.0 


2 


5 


0.5 


3.6 





2-12 



MAINTENANCE SPECIFICATIONS 



SPEC 


M 



TIGHTENING TORQUE: 






Parts to be tightened 


Parts name 


Thread Size 


Q'ty 


Tightening Torque 


Remarks 


Nm 


m»kg 


ft-lb 


Pad adjuster & Lock nut 


Nut 


M8X1.25 


1 


16 


1.6 


11 




(Rear brake caliper) 
















Brake hose & Frame 


Bolt 


M8X1.25 


2 


20 


2.0 


14 




Flare nut & Joint 


Nut 


M10X1.0 


4 


18 


1.8 


13 





NOTE: 

Apply locking agent (LOCTITE® ) to ring nuts threads. 

1st: Tighten the inside ring nut 55 Nm (5.5 nrrkg, 40 ft*lb). 

2nd: Tighten the outside ring nut while holding the inside ring nut 190 Nm (19 m«kg, 140 ft«lb). 

3rd: Loosen the inside ring nut while holding the outside ring nut 240 Nm (24 m»kg, 170 ft-lb). 



2-13 



MAINTENANCE SPECIFICATIONS 


SPEC 


p? 


ELECTRICAL 


Model 






YFM350XA 


Voltage 




12V 


Ignition System: 
Ignition Timing (B.T.D.C.) 
Advanced Timing 
(B.T.D.C.) 
Advancer Type 


10° at 1,000 r/min 
33° at 5,000 r/min 

Electrical 


i°\ 






















30 


















en 




















c _ 

1 <-? 20 - 






















/ 














O h- 

t~ 10 n 
- 




/ 




























































I 








12 3 4! 
Engine speed 


5 6 7 8 9 10 
(x10 3 r/min) 


C.D.I: 

Magneto-Model/Manufacturer 
Pickup Coil Resistance 

(Color) 
Source Coil Resistance 

(Color) 
C.D.I. Unit-Model/Manufacteur 


F3T43573/MITSUBISHI 

171-2090 at20°C (68°F) 

(Y-L) 

270-3300 at20°C (68°F) 

(W/G-R) 

F8T30572/MITSUBISHI 


Ignition Coil: 
-Model /Manufacturer 
Minimum Spark Gap 
Primary Winding Resistance 
Secondary Winding Resistance 


F6T535 

6 mm (0.236 in) 
0.36-0.480 at20°C (68°F) 
5.44-7.36K0 at 20°C (68°F) 


Spark Plug Cap: 
Type 
Resistance 


Resin type 
10KO 


F.W. Magneto: 
Model/ Manufacturer 
Charging Current-(Min) 
-(Max) 
Charging Coil Resistance 
(Color) 


F3T43573/MITSUBISHI 
12A or more at 3,000 r/min 
17A or more at 8,000 r/min 
0.70-0.860 at20°C (68°F) 
(W-W) 


Voltage Regulator: 
-Type 

-Model/manufacturer 
-No Load Regulated Voltage 


Semi conductor-Short circuit 
SH235-12/SHINDENGEN 
14.0-15.0 V 



2-14 



MAINTENANCE SPECIFICATIONS 



SPEC 


PI 



Model 


YFM350XA 


Rectifiter; 

-Model/ Manufacturer 
Capacity 
Withstand Voltage 


SH235-12/SHINDENGEN 

15A 

240V 


Battery: 
Specific Gravity 


1.280 


Electric Starter System: 
Type 


Constant Mesh 


Starter Motor: 
Model/ Manufacturer 
Out put 

Armature Coil Resistance 
Brush Overall Length 

(Min) 
Brush Spring Pressure 
Commutator Dia 

(Min) 
Mica Undercut 


DB5DT/NIPPONDENSO 

0.7 Kw 

0.011-0.0130 at20°C (68°F) 

12 mm (0.47 in) 

8.5 mm (0.33 in) 

650-950 g (22.9-33.5 oz) 

28 mm (1.10 in) 

27 mm (1.06 in) 

0.6 mm (0.024 in) 


Starter Switch: 
Model/Manufacturer 
Amperage Rating 
Coil Winding Resistance 


MS5D-191/HITACH 

100A 

3.9-4.70 


Circuit Breaker: 
Type 
Amperage for Individual. 

Circuit x Quantity 

Main 


Fuse 
15Ax1 



2-15 



GENERAL TORQUE SPECIFICATIONS/ 
DEFINITION OF UNITS 



SPEC 


Pf 



GENERAL TORQUE 
SPECIFICATIONS 

This chart specifies torque for standard fasteners 
with standard I.S.O. pitch threads. Torque specifi- 
cations for special components or assemblies are 
included in the applicable sections of this book. 
To avoid warpage, tighten multi-fastener assem- 
blies in a crisscross fashion, in progressive stages, 
until full torque is reached. Unless otherwise 
specified, torque specifications call for clean, dry 
threads. Components should be at room tem- 
perature. 



A 
(Nut) 


B 
(Bolt) 


General torque 
specifications 


Nm 


m*kg 


ft. lb 


10 mm 


6 mm 


6 


0.6 


4.3 


12 mm 


8 mm 


15 


1.5 


11 


14 mm 


10 mm 


30 


3.0 


22 


17 mm 


12 mm 


55 


5.5 


40 


19 mm 


14 mm 


85 


8.5 


6.1 


22 mm 


16 mm 


130 


13.0 


94 




A: Distance across flats 
B: Outside thread diameter 



DEFINITION OF UNITS 



Unit 


Read 


Definition 


Measure 


mm 
cm 


millimeter 
centimeter 


10 ~ 3 meter 
10 ~ 2 meter 


Length 
Length 


kg 


kilogram 


10 3 gram 


Weight 


N 


Newton 


1 kgxm/sec 2 


Force 


Nm 
m«kg 


Newton meter 
Meter kilogram 


Nxm 
mxkg 


Torque 
Torque 


Pa 
N/mm 


Pascal 

Newton per millimeter 


N/m 2 
N/mm 


Pressure 
Spring rate 


L 

cm 3 


Liter 

Cubic centimeter 


- 


Volume 
or capacity 


r/min 


Rotation per minute 


- 


Engine speed 



2-16 



LUBRICATION DIAGRAMS 



LUBRICATION DIAGRAMS 

® Camshaft 
(D Oil cleaner 
(D Main axle 
@ Drive axle 
(5) Crankshaft 
© Oil filter 

(7) Oil pump 

(8) Counter axle 
(D Out-put axle 



SPEC 


P? 













/[oh 












JG?» 


J*\r \SQx 


© 








iff 


—\ xolA^t^ 






(o\ 


(0/ /J\X 




n x® //W 




Jo/ 








( < vl\_ f?^ I 1 


f *^^ // '^~ 




\^-Jptr 








// \m /4k/ 






L~J£r-® 


-© 




(§r^ 




^^Zl^j \j 


_o/ 


W (q (§)) 






fepi^sss^^ 








^fr'i^jD^ J5 




dr 













2-17 



LUBRICATION DIAGRAMS 



LUBRICATION DIAGRAMS 



(T) Camshaft 
(I) Oil cleaner 
(3) Main axle 
@ Drive axle 
(5) Crankshaft 



© Oil filter 
© Oil pump 
® Counter axle 
(|) Out-put axle 



SPEC 


P? 




2-18 



CABLE ROUTING 

(T) Brake hose 
(5) Clutch switch 
(D Brake cable 

(4) Clutch cable 

(5) Brake hose 

(6) Thbrottle cable 

(7) Band 

(8) Handlebar switch (Left) 
(D Main switch 



CABLE ROUTING 



SPEC 


P? 



[A] Pass the breather pipe through the hole on 

the handlebar protector. 
\E\ Route outside the clamp and between the 

wire harness and the frame pipe. 
\£\ Route inside the throttle cable and brake hose. 




2-19 



CABLE ROUTING 



SPEC 


Pt 



Ground bolt 

Headlight 

To right headlight 

Main switch cord 

Clutch switch cord 

Handlebar switch lead 

Band 

Main switch 

Pilot lamp 

Air vent hose 

Fuel hose 

Crankcase breather hose 

Ground lead 

Carburetor overflow hose 

Starter relay 

Starting circuit cut-off relay 



Neutral switch relay 
Fuse holder 
Taillight unit 
Battery breather hose 
Rubber boot 
Reservoir hose 
Clamp 

Neutral switch lead 
CDI magneto lead 
Fuel tank breather hose 
Clamp the leads securely and 
the band must be tight. 
Install the main switch on the 
right side of the front panel. 
Pass the air vent hose through 
the hole on the fuel tank rubber 
damper. 



10 



E 



B 



El 



tD 



Pass the carburetor overflow 

hose between the rear arm head 

pipe and the rear shock absorber. 

Pass the carburetor overflow 

hose through the holder on the 

frame. 

Pass the brake hose along the 

curve of the cleaner case. 

Clamp the cable lead. 

Clamp the CDI magneto lead. 

Route behind the breather pipe. 

Pass the throttle cable through 

the holder. 

Pass the battery breather hose 

through the inside of frame 

bracket. 

Pass the battery breather hose 

through the holder. 




2-20 



Ground screw 

(D Rear shock absorber 

<D Starter motor lead 

(4) Starter motor 

(5) Brake hose 

© Reverse switch 
(7) Brake cable 
® Brake hose 
® Rectifier/ Regulator 
(Jd CDI unit 



CABLE ROUTING 



SPEC 


;Jf 



[A] The leads must be forked up. 
El Pass the wire harness and 

starter motor lead through 

the holder. 
El Route the leads in front of 

the fuel tank securing bolt 

(Right side). 
IS Route behind the starter 

motor lead. 



[U Pass the lead through the 
welded holder on the frame. 

\E Route behind the clutch 
cable and brake cable. 

|Q] Route cutside the reservoir 
hose. 




2-21 



© Ignition coil 
(D Pilot lamp (Neutral) 
(D Wire harness 
@ Battery 

§ Positive lead 
Switch cord clamp 
(7) Pilot lamp (Reverse) 



CABLE ROUTING 



SPEC 0/ 



[A] Aligh the marking tape at the position of 

the clamp. 
E] Pass the leads through the hole on the rear 

fender. 
[2 Route the positive lead carefully. 




2-22 



INSP 


WA 


ADJ 



INTRODUCTION/PERiODIC MAINTENANCE/ 
LUBRICATION 

PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perform recommended inspections and adjustments. 
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and 
a longer service life. The need for costly overhaul work will be greatly reduced. This information ap- 
plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service 
technicians should be familiar with this entire chapter. 

PERIODIC MAINTENANCE/LUBRICATION 



Item 


Remarks 


Initial 


Every 


1 
month 


3 

months 


6 

months 


6 
months 


1 

year 


Valve(s)* 


Check valve clearance. Adjust if necessary. 


O 




O 





O 


Spark plug(s) 


Check condition. Clean or replace if necessary. 


O 








O 


o 


Air filter 


Clean. Replace if necessary. 







o 


o 


o 


Carburetor* 


Check idle speed/starter operation. 
Adjust if necessary. 




o 


o 


o 


o 


Fuel line* 


Check fuel hose for cracks or damage. 
Replace if necessary. 






o 





o 


Engine oil 


Replace (Warm engine before draining). 


o 




o 








Engine oil filter 


Replace 






o 





o 


Engine oil strainer 


Clean 















Drive chain 


Check and adjust slack/alignment/clean /lube. 


o 


o 


o 





o 


Brake* 


Check operation. Adjust if necessary. 


b 














Clutch* 


Check operation. Adjust if necessary. 


o 




o 


o 





Wheels* 


Check balance/damage/ runout. 
Repair if necessary. 


o 




o 


o 





Wheel bearings* 


Check bearings assembly for looseness/damage. 
Replace if damaged. 


o 




o 


o 





Steering system* 


Check operation /replace if damaged. 
Check toe-in /adjust if necessary. 





o 


o 





o 


Lower arm pivot and 
steering shaft* 


Lubricate every 6 months.*** 






o 





o 


Rear arm pivot* 


Lubricate every 6 months.*** 






o 


o 





Fittings/ Fasteners* 


Check all chassis fittings and fasteners. 
Correct if necessary. 


o 


o 


o 


o 


o 


Battery* 


Check specific gravity. 

Check breather pipe for proper operation. 

Correct if necessary. 





o 


o 










It is recommended that these items be serviced by a Yamaha dealer. 
Medium weight wheel bearing grease. 
Lithium soap base grease. 



3-1 



VALVE CLEARANCE ADJUSTMENT 



INSP 


09 


ADJ 




WB2AA003 

ENGINE 

VALVE CLEARANCE ADJUSTMENT 
NOTE: 

• The valve clearance should be adjusted 
when the engine is cool to the touch. 

• The piston must be at Top Dead Center 
(TDC) on compression stroke to check or 
adjust the valve clearance. 

1. Remove: 
•Seat 



2. Remove: 

• Head lightunit assembly 



3. Remove: 

• Main switch (D 

• Front panel (D 



4. Remove: 
• Front fender 



3-2 



VALVE CLEARANCE ADJUSTMENT 



INSP 


Wl 


ADJ 




5. Turn the fuel cock to the "OFF" (D posi- 
tion. 

6. Disconnect: 
• Fuel hose (D 



7. Remove: 
• Fuel tank 



8. Remove: 

• Tappet cover (D (intake) 

• Tappet cover (2) (exhaust) 



9. Remove: 

• Timing window plug 



10. Check: 
• Valve clearance 
Out of Specification -> Adjust 



& 


Valve clearance (cold): 


^\ 


Intake valve 




0.06 ~ 0.10 mm 




(0.00236 ~ 0.00394 in) 




Exhaust valve 




0.16 ~ 0.20 mm 




(0.00630 — 0.00787 in) 



3-3 



VALVE CLEARANCE ADJUSTMENT 



INSP 


03 


ADJ 




************************************* 

Checking steps: 

• Turn the crankshaft counterclockwise 
with a wrench. 

• Align the "T" mark (D on the crankshaft 
web with the stationary pointer (D . 



• Measure the valve clearance by using a 

feeler gauge (3) . 

************************************* 



11. Adjust: 

• Valve clearance 

************************************* 

Adjustment steps: 

• Loosen the locknut (D . 

• Insert the feeler gauge (3) between the ad- 
juster end and the valve end. 



• Turn the adjuster (2) in or out with the 
valve adjusting tool (D until specified 
clearance is obtained. 



Turning in -* Valve clearance is decreased. 



Turning out -» Valve clearance is increased. 



¥* 



Valve adjusting tool: 
P/N YM-08035 



• Hold the adjuster to prevent it from 
moving and thoroughly tighten the locknut. 




Locknut: 
20 Nm (2.0 m- kg,14ft* lb) 



3-4 



VALVE CLEARANCE ADJUSTMENT/ 
SPARK PLUG INSPECTION 



INSP 


pa 


ADJ 



• Measure the valve clearance. 

• If the vatve clearance is incorrect, repeat 
above steps until the specified clearance is 
obtained. 




12. Install: 

• Tappet cover(exhaust) 

• Tappet cover(intake) 
NOTE: 



• Install the tappet covers with their ridge 
facing upward (D . 

• Check the o-rings ® for damage. If dama- 
ged, replace. 




Tappet cover: 

10 Nm (1.0 m* kg,7.2ft* lb) 



13. Install: 

• Timing window plug 



WB2AA009 

SPARK PLUG INSPECTION 

1. Remove: 

• Spark plug 

2. Inspect: 

• Spark plug type 
lncorrect-»Replace. 



3-5 



SPARK PLUG INSPECTION 




INSP 


Wd 


ADJ 



Standard spark plug: 
D8EA (N.G.K.) 
X24ES-U (N.D.) 



3. Inspect: 

• Electrode (D 
Wear/Damage-»Replace. 

• Insulator (2) 
Abnormal color-»Replace 

Normal color is a medium-to-light tan color. 

4. Clean the spark plug with a spark plug 
cleaner or wire brush. 



5. Measure: 
• Plug gap (a) 

Use a Wire Gauge or Feeler Gauge. 

Out of specification-»Replace. 




Spark plug gap: 

0.6 ~ 0.7 mm (0.024 



0.028 in) 



7. Tighten: 
• Spark plug 




Spark plug: 

17.5 Nm (1.75 m • kg, 12.5 ft • lb) 



NOTE: 

• Before installing a spark plug, clean the 
gasket surface and plug surface. 

• If a torque wrench is not available when 
you are installing a spark plug, a good esti- 
mate of the correct torque is 1/4 to 1/2 
turns part finger tight. Have the spark plug 
torque to the correct value as soon as pos- 
sible with a torque wrench. 



3-6 



CRAIMKCASE VENTILATION SYSTEM/FUEL LINE/ 
INTAKE MANIFOLD/EXHAUST SYSTEM 



INSP 


09 


ADJ 




WB000001 

CRANKCASE VENTILATION SYSTEM 

1. Remove: 

• Seat 

2. Inspect: 

• Crankcase ventilation hose CD 
Cracks/Damage-»Replace. 



WB000002 

FUEL LINE 

1. Inspect: 
• Fuel hoses 
Cracks/Damage-»Replace. 



WB0OO0O3 

INTAKE MANIFOLD 

1 . Tighten: 

• Carburetor clamps 

• Carburetor joint bolts 

2. Inspect: 

• Carburetor joint 

• Gaskets 
Cracks/Damage-»Replace. 




WB0000O4 

EXHAUST SYSTEM 

1. Inspect: 

• Exhaust pipe gasket(s) (D 
Damage-»Replace. 
Exhaust gas leakage~»Repair. 

2. Tighten: 

• Exhaust pipe bolts 

• Muffler bolts 



\ 


Exhaust pipe nut (2) : 


12 Nm (1.2 m* kg,8.7 ft • lb) 




Muffler mounting bolt (3) : 




27 Nm (2.7 m* kg, 19 ft- lb) 




Exhaust pipe/Muffler clamp 




bolt ® : 




20 Nm (2.0 m • kg, 14 ft * lb) 




Protector screws © : 




8 Nm (0.8 m • kg f 5.8 ft • lb) 



3-7 



IDLING SPEED ADJUSTMENT 



INSP 


ra 


ADJ 



WB3AE004 

IDLING SPEED ADJUSTMENT 

1 . Start the engine and let it warm up for se- 
veral minutes. 



2. Attach: 

• Inductive tachometer (to the spark plug 
lead). 



¥* 



Inductive tachometer: 
P/N YU-8036-A 



3. Check: 

• Engine idling speed 
Out of specification -> Adjust. 



A 



Engine idling speed: 
1,450 ~ 1,550 r/min 



4. Adjust: 

• Engine idling speed 

ft************************************ 

Adjustment steps: 

• Turn in the pilot air screw (D until it is ligh- 
tly seated. 

• Turn out the pilot air screw for the speci- 
fied number of turns. 




Pilot air screw: 1 and 1/4 turns out 



Turn the throttle stop screw (2) in or out 
until specified idling speed is obtained. 



Turning in->ldling speed becomes higher. 



Turning out-Hdling speed becomes lower. 



***•#**•*************•##***********«« 



3-8 



TIMING CHAIN ADJUSTMENT/ 
ENGINE OIL LEVEL INSPECTION 



INSP 


Wl 


ADJ 



5. Adjust: 

• Throttle cable free play 

Refer to "THROTTLE CABLE FREE PLAY 

ADJUSTMENT" section. 




Free play: 
3 — 5 mm (0.12 



0.20 in) 



WB2AA0O8 

TIMING CHAIN ADJUSTMENT 

Adjustment free. 




10 


30 50 70° F 




A , 


1 1 1 




( Yamalube 4 (10W30) or SAE 10W30 




M 


\A 1 1 




[(Yamalube 4 (20W40I or SAE 20W40 








K ^ 










SAE 5W30 )j 






I 




-10 


10 20°C 



WB000006 

ENGINE OIL LEVEL INSPECTION 

1 . Place the machine on a level surface. 

2. Inspect: 
• Oil level 

Oil level should be between maximum 

and minimum (2) marks. 

Oil level low-»Add oil to proper level. 



<D 



NOTE: 

Do not screw the dipstick ® . Insert the dip- 
stick tightly when inspecting the oil level. 



*& 



Recommended oil: 

Follow the left chart. 



NOTE: 

Recommended oil classification: 

API Service"SE\"SF"type or equivalent (e.g. 

"SF-SE-CCYSF-SE-SD"etc). 



Do not allow foreign material to enter the 
crankcase. 



3-9 



ENGINE OIL REPLACEMENT 



INSP 


P9 


ADJ 




3. Start the engine and let It warm up for se- 
veral minutes. 

4. Stop the engine and inspect the oil level 
once again. 

NOTE: 

Wait a few minutes until level settles before 
inspecting the oil level. 



ii WARNING 



Never attempt to remove the dipstick just 
after high speed operation. The heated oil 
could spout out, causing danger. Wait until 
the oil cools down. 



WB000006 

ENGINE OIL REPLACEMENT 

1 . Place the machine on a level surface. 

2. Start the engine and let it warn up for se- 
veral minutes. 

3. Stop the engine and place an oil pan under 
the engine. 



4. Remove: 

• Dipstick 

• Drain plug <D (crankcase) 
•O-ring ® 

• Compression spring (D 

• Oil strainer (4) 

Drain the crankcase of its oil. 



When removing the drain plug the compres- 
sion spring, oil strainer and o-ring will fall 
off. Take care not to lose these parts. 



3-10 



ENGINE OIL REPLACEMENT 



INSP 


Fa 


ADJ 




5. if the oil filter is replaced with oil change, 
remove the following parts and reinstall 
then. 

• Oil filter cover (D 

• Oil filter <D 



************************************* 

Installation steps: 

• inspect the o-ring ® . If it is damaged, rep- 
lace it with a new one. 

• Apply lithium soap base grease to the o- 
ring. 

• Install the oil filter, o-ring and oil filter 
cover. 




Boltstoil filter cover): 

10 Nm (1.0 m- kg, 7.2 ft- lb) 



************************************* 



6. Install: 

• Oil strainer 

• Compression spring 

• O-ring 

• Drain plug(crankcase) 
NOTE: 



Inspect the o-ring. If it is damaged, replace it 
with a new one. 



: !0gm6^. ; 

Before reinstalling the drain plug, do not 
forget to fit the o-ring, compression spring 
and oil strainer. Be sure you fit each item in 
the correct position and order. 



3-11 



ENGINE OIL REPLACEMENT 



INSP 


EU 


ADJ 



X 



Drain plug(crankcase): 
43 Nm (4.3 m -kg, 31 ft- lb) 



7. Fill: 

• Crankcase 






Oil quantity: 
With oil filter change 
2.5L (2.2 Imp qt, 2.6 US qt) 
Without oil filter change 
2.4L(2.1lmpqt,2.5USqt) 



Refer to the "ENGINE OIL LEVEL INSPEC- 
TION" section. 



9. Inspect: 

• Oil flow 

Inspection steps: 

• Slightly loosen the oil gallery bolt ® in the 
cylinder head. 




• Start the engine and keep it idling until oil 
begins to seep from the oil gallery plug. If 
no oil comes out after one minutes, stop 
the engine immediately so it will not engine 
stick. 

• Restart the engine after solving the prob- 
lem(s), and recheck the oil pressure. 

• Tighten the oil gallery plug to specification. 



3-12 



CLUTCH ADJUSTMENT/IGNITION TIMING CHECK 



INSP 


ra 


ADJ 





Oil gallery plug: 
7 Nm (0.7 m • kg ,5.1 ft- lb) 



#*»*»»»»»*#»#»»**##«»#####*##*»**♦### 



WB2AFOOO 

CLUTCH ADJUSTMENT 

1. Check: 

• Clutch cable free play (D 
Out of specification -> Adjust. 



^ 


Free play: 


A 


5 ~ 10 mm (0.2 ~ 0.4 in) 


\ 


at clutch lever end 



2. Adjust: 

• Clutch cable free play 

*#»****************»*#*»♦*###*»**»##* 

Adjustment steps: 

• Loosen the tocknut(s) (D . 

• Turn the adjuster(s) (D in or out until the 
specified free play is obtained. 



Turning in -> Free play is increased. 



Turning out -» Free play is decreased. 



• Tighten the locknut(s). 

*^('^^'^^'l^#'^^'^("^^^^'^^^^^fr , ^t'*'^( , ^^'^l''^^#^^*4^^^'#^^*'^('^^^^■l^#')nt'^^#•^^ 



WB3AA013 

IGNITION TIMING CHECK 
NOTE: 



Engine idling speed and throttle cable free 
play should be adjusted properly before chec- 
king the ignition timing. 



1 . Remove: 
• Plug 



3-13 



IGNITION TIMING CHECK/ 
COMPRESSION PRESSURE MEASUREMENT 



INSP 


ffy 


ADJ 



<<s8P^ 




@¥ 2. Attach: 
I • Timing light and inductive tachometer 
{To the spark plug lead.) 



P 



Timing light: 

P/N YM-33277-A 
Inductive tachometer: 

P/N YU-8036-A 



3. Check: 

• Ignition timing 

*******#**#*###*##****»*##*♦♦*******# 

Checking steps: 

Warm up the engine and keep it at the spe- 





d 


V3) 


cified speed. 
















A 


Engine speed: 

1,450—1,550 r/min 



• Visually check the stationary pointer (2) 
to verify it is within the required firing 
range (D indicated on the flywheel. 
Incorrect firing range-»Check flywheel and 

/or pickup assembly(tightness damage). 

************************************* 

4. Install: 
•Plug 



WB3AB002 

COMPRESSION PRESSURE MEASURE- 
MENT 

NOTE: 

Insufficient compression pressure will result 
in performance loss. 



3-14 



COMPRESSION PRESSURE MEASUREMENT 



INSP 


e*a 


ADJ 



1. Check: 

• Valve clearance 
Out of specif ication-* Adjust. 
Refer to the "VALVE CLEARANCE ADJUS- 
TMENT" section. 




2. Start the engine and let it warm up for se- 
veral minutes. 

3. Stop the engine. 

4. Remove: 
• Spark plug 



5. Attach: 

• Compression gauge (D 



/* 



Compression gauge: 
P/N YU-33223 



6. Measure 

• Compression pressure 

Above the maximum pressure -» 
Inspect cylinder head, valve surfaces, and 
piston crown for carbon deposits. 
Below the minimum pressure -> 
Squirt a few drops of oil into affected cylin- 
der and measure again. 

• Follow the table below. 



Compression pressure 
(With oil applied into cylinder) 


Reading 


Diagnosis 


Higher than 
without oil 


Worn or damaged pistons 


Same as wi- 
thout oil 


Defective ring(s), valves, cylin- 
der head gasket or piston is po- 
ssible. 



3-15 



COMPRESSION PRESSURE MEASUREMENT/ 

AIR FILTER CLEANING 



INSP 


By 


ADJ 



Compression pressure (at sea level): 


Standard: 




850 kPa (8.5 kg/cm 2 . 


121 psi) 


Minimum: 




800 kPa (8.0 kg/cm 2 . 


114 psi) 


Maximum: 




900 kPa (9.0 kg/cm 2 . 


128 psi) 



Measurement steps: 

• Crank over the engine with the electric 
starter (be sure the battery is full charged) 
with the throttle wide-open until the com- 
pression reading on the gauge stabilizes. 



^WARNING 



When cranking the engine, ground all spark 
plug leads to prevent sparking. 



• Repeat the previous steps for the other 
cylinders. 



NOTE: 

The difference of compression pressure bet- 
ween the highest and lowest cylinder com- 
pression readings should be 100 kpa (1 kg/ 
cm 2 , 14 psi) or less. 




WB2AB005 

AIR FILTER CLEANING 

NOTE 

There is the check hose (D at the bottom of 
the air filter case. If dust and/or water collec- 
ts in this hose, clean the air filter element 
and air filter case. 



3-16 



AIR FILTER CLEANING 



INSP 


B"3 


ADJ 





1 . Remove: 
•Seat 

• Air filter case cover 

• Air filter assembly (D 

NOTE: 

Turn the hook (2) 90° clockwise and 
remove the air filter from the guide. 



NOTE: 

Each time filter maintenance is performed, 
check the air inlet to the filter case for obs- 
tructions, check the air cleaner joint rubber 
to the carburetor and manifold fittings for an 
air-tight seal. Tighten all fittings thoroughly 
to avoid the possibility of unfiltered air en- 
tering the engine. 



Never operate the engine with the air filter 
element removed. Unfiltered air will cause 
rapid wear of engine parts and possible 
engine damage. Additionally, operation wi- 
thout the filter element will affect carbure- 
tor tuning with subsequent poor performan- 
ce and possible engine overheating. 



2. Inspect: 

• Air filter element 
Damaged -» Replace. 

3. Clean: 

• Air filter element 




it************************************ 

Cleaning steps: 

• Wash the air filter gently, but thoroughly 
in solvent (D . 



ik WARNING 



Use parts cleaning solvent only. Never use 
gasoline or low flash point solvents which 
may lead to fine or explosion. 



3-17 



AIR FILTER CLEANING 



INSP 


R 


ADJ 



Squeeze the excess solvent out of the air 
filter and let dry. 



Do not twist or wring out the air filter. This 
could damage the foam material. 



• Apply the engine oil (D . 



Squeeze out the excess oil. 



NOTE: 

The air filter should be wet but not dripping. 



******#***######*##############**######## 




4. Install: 
• Air filter 

(onto the guide) 
NOTE: 



Turn the hook (D 90°counterclockwise. 



5. Install: 

• Air filter assembly 

(into the air filter case) 
NOTE: 



• Insert the lobes on the element guide into 
the receptacles on the filter case. 

• Make sure that the sealing surface of the 
air filter matches the sealing surface of the 
case so there is no air leak. 



6. Install: 

• Cover(air filter case) 

•Seat 



3-18 



THROTTLE CABLE ADJUSTMENT 



INSP 


P9 


ADJ 



WB2AE009 

THROTTLE CABLE ADJUSTMENT 

NOTE: 

Before adjusting the throttle cable free play, 
the engine idling speed should be adjusted. 



; mm ic» ! 

Before adjusting the throttle lever free play, 
make sure that the adjusters and locknuts 
on the carburetor side are fully tightened. If 
not, the throttle does not operate properly. 




1. Check: 

• Throttle cable flee play (a) 
Out of specification -» Adjust. 



^ 


Free play: 


^\ 


3 ~ 5 mm (0.12 ~ 0.20 in) 


\ 


at throttle lever end. 



2. Remove 
•Seat 

• Main switch 

• Front panel 

• Front fender 

• Fuel tank 

Refer to "VALVE CLEARANCE ADJUST- 
MENT" section. 




3. Adjust: 

• Throttle cable free play 

ft************************************ 

Adjustment steps: 
First step: 

• Loosen the locknut (D . 

• Turn the adjuster <D in or out until the spe- 
cified free play is obtained. 



3-19 



THROTTLE CABLE ADJUSTMENT 



INSP 


09 


ADJ 



Turning in -» Free play is increased. 



Turning out -> Free play is decreased. 



• Tighten the locknut. 



x 



Locknut: 
1Nm(0.1m* kg, 0.7 ft- lb) 




NOTE: 

If the free play cannot be adjusted here, 
adjust it at the throttle lever side of the 
cable. 



Final step: 

• Loosen the locknut (D . 

• Turn the adjuster (D in or out until the spe- 
cified free play is obtained. 



Turning in -» Free play is increased. 



Turning out ~> Free play is decreased. 



Tighten the locknut. 



^WARNING 



After adjusting, turn the handlebar to the 
right and left, making sure that the engine 
idling speed does not run faster. 



4. Install: 

• Fuel tank 

• Front fender 

• Front panel 

• Main switch 

• Seat 



3-20 



SPEED LIMITER ADJUSTMENT 



INSP 


pa 


AOJ 




WB000007 

SPEED LIMITER ADJUSTMENT 

The speed limiter keeps the carburetor throt- 
tle from becoming full-open even when the 
throttle lever is pushed to a maximum. Scre- 
wing in the adjuster stops the engine speed 
from increasing. 



1 . Adjust: 

• Speed limiter length (a) 



************************************* 

Adjustment steps: 

• Loosen the locknut (D . 

• Turn the adjuster (D in or out until the 
proper length is attained. 




Standard length: 
12mm(0.47in) 



Tighten the locknut. 



ikWARNING 



• Particularly for a beginner rider, the 
speed limiter should be screwed in comple- 
tely. Screw it out little by little as riding te- 
chnique improves. Never remove the 
speed limiter from the outset. 

• For proper throttle lever operation do not 
turn out the adjuster more then 12mm 
(0.47in). Also adjust the throttle lever 
cable play always to 3 — 5mm(0.12 ~ 
0.20in). 

************************************* 



3-21 



BRAKE PAD INSPECTION/ 
BRAKE FLUID LEVEL INSPECTION 



INSP 


Wd 


ADJ 




WB2A3009 

CHASSIS 

BRAKE PAD INSPECTION 
Front brake pad: 

1 . Activate the brake lever or brake pedal. 

2. Inspect: 

• Brake pad 
Wear indicator (D almost contacts brake 
disc->Replace brake pad as a set. 

Refer to the "BRAKE PAD REPLACEMENT" 
section. 




Rear brake pad: 

1 . Depress the brake lever. 

2. Inspect: 

• Brake pads 
wear indicator (D almost contacts disc -* 
Replace pads. 

Refer to the "BRAKE PAD REPLACEMENT" 
section. 



WB2A3008 

BRAKE FLUID LEVEL INSPECTION 

1 . Place the machine on a level surface. 

2. Inspect: 

• Fluid level 
Fluid level is under "LOWER" level line (D 
->Replenish. 



*0 



Recommended fluid: 
DOT No.4 

If DOT No4is not available, 
No.3 can be used 



3-22 



BRAKE FLUID LEVEL INSPECTION/ 
FRONT BRAKE ADJUSTMENT 



INSP 


By 


ADJ 



NOTE: 

• If DOT No.4 is not available, DOT No.3 can 
be used. 

• When inspecting the fluid level of the reser- 
voir at the handlebars, make sure the 
master cylinder top is horizontally level. 




: :<mW«ONI: :: , 

The fluid may erode painted surfaces or pla- 
stic parts. Always clean up spilled fluid im- 
mediately. 



AWARNING 



• Use only the designated quality fluid: 
otherwise, the rubber seals may deteriora- 
te, causing leakage and poor brake perfor- 
mance. 

• Refill with the same type of fluid; mixing 
fluids may result in a harmful chemical rea- 
ction and lead to poor performance. 

• Be careful that water does not enter the 
master cylinder when refilling. Water will 
significantly lower the boiling point of the 
fluid and may result in vapor lock. 



WB2A300O 

FRONT BRAKE ADJUSTMENT 

1. Check: 

• Brake lever free play (a) 
Out of specification-Mdjust. 



^ 


Free play: 


A 


4~8mmt0.16~0.31in) 




at brake lever end 



2. Adjust: 

• Brake lever free play 

Adjustment steps: 

• Loosen the locknut(s) CD . 

• Turn the adjuster (2) in or out until the spe- 
cified free play is obtained. 



3-23 



FRONT BRAKE ADJUSTMENT/ 
REAR BRAKE ADJUSTMENT 




INSP 


m 


ADJ 



Turning in-»Free play is increased. 



Turning out-»Free play is decreased. 



• Tighten the locknut. 



ft************************************ 



Make sure that the brake does not drag 
after adjusting it. 



AWARMING 



A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. This air must be removed by blee- 
ding the brake system before the motorcyc- 
le is operated. Air in the system will cause 
greatly diminished braking capability and 
can result in loss of control and an accident. 
Inspect and bleed the system if necessary. 

WB2A3004 

REAR BRAKE ADJUSTMENT 

1. Check: 

• Brake pedal height (a) 
Out of specif ication-»Adjust. 




Brake pedal height: 
10 mm (0.4 in) 
below top of f ootrest 



2. Adjust: 

• Brake pedal height 

Adjustment steps: 

• Loosen the locknut (D 

• Turn the adjuster (D in or out until the spe- 
cified pedal height is obtained. 



3-24 



REAR BRAKE ADJUSTMENT 




INSP 


09 


ADJ 



Turning in->Pedal height is increased. 



Turning out-*Pedal height is decreased. 



AWARMING 



After adjusting the brake pedal height, vi- 
sually check the adjuster end. The adjuster 
end must appear within 6.25 mm (0.25 in). 



Tighten the locknut. 



\ 



Locknut: 

18 Nm (1.8 m- kg, 13 ft- lb) 



**********#**##»**##*###**#»*****»#* j 



BNNH 

Make sure that the brake does not drag 
after adjusting it. 



^WARNING 



A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. This air must be removed by blee- 
ding the brake system before the motorcyc- 
le is operated. Air in the system will cause 
greatly diminished braking capability and 
can result in loss of control and an accident. 
Inspect and bleed the system if necessary. 



3. Adjust: 

• Brake light switch 
Refer to the "BRAKE LIGHT SWITCH AD- 
JUSTMENT" section. 



3-25 



PARKING BRAKE ADJUSTMENT 



INSP 


Fa 


ADJ 




WB000008 

PARKING BRAKE ADJUSTMENT 

1. Adjust: 

• Parking brake 

a************************************ 

Parking brake adjustment steps: 

• Apply rear brake pedal 2 or 3 times. 



• Loosen the locknut (D and fully loosen the 
parking brake cable adjuster (2) on the left 
lever holder. 

• Loosen the locknut (D and adjusting bolt 
(4) on the rear caliper. 

• Slowly screw in the adjusting bolt by 
tool until it feels tight and screw it out 1/4 
turn. Then tighten the locknut (3) . 



Locknut (D : 

16 Nm (1.6 m- kg, 11 ft • lb) 



m&mm 

When tightening the locknut, hold the adjus- 
ting bolt with a spanner so that the adjus- 
ting bolt is not turned together with the loc- 
knut. 



• Adjust parking brake cable length (D by 
turning cable adjuster (2) in or out. 




Parking brake cable length: 
46~50mm(1.81~1.97in) 



• Tighten the locknut CD 



A WARN I IMG 



After this adjustment is performed, block 
the rear of the machine off the ground, and 
spin the rear wheels to ensure there is no 
brake drag. If any brake drag is noticed, per- 
form the above step again. 

************************************* 



3-26 



AIR BLEEDING 



INSP 


ra 


ADJ 



WB2A3013 

AIR BLEEDING 

(HYDRAULIC BRAKE SYSTEM) 



AWARIMIIMG 



Bleed the brake system if: 

• The system has been disassembled. 

• A brake hose has been loosened or remo- 
ved. 

• The brake fluid is very low. 

• The brake operation is faulty. 

A dangerous loss of braking performance 
may occur if the brake system is not proper- 
ly bled. 




1. Bleed: 

• Brake fluid 

***#*#♦»*#************##**»********** 

Air bleeding steps: 

• Add proper brake fluid to the reservoir. 

• Install the diaphragm. Be careful not to 
spill any fluid or allow the reservoir to over- 
flow. 

• Connect the clear plastic tube (D tightly 
to the caliper bleed screw. 

• Place the other end of the tube into a con- 
tainer. 

• Slowly apply the brake lever or pedal se- 
veral times. 

• Pull the lever in or push down on the pedal. 
Hold the lever or pedal in position. 



• Loosen the bleed screw and allow the 
lever or pedal to travel towards its limit. 

• Tighten the bleed screw when the lever or 
pedal limit has been reached; then release 
the lever or pedal. 



\ 



Bleed screw: 
5 Nm (0.5 m • kg, 3.6 ft • lb) 



3-27 



DRIVE CHAIN SLACK ADJUSTMENT 



INSP 


w& 


ADJ 




• Repeat above steps until the air bubbles 
have been removed from the system. 

NOTE: 

If bleeding is difficult, it may be necessary to 
let the brake fluid system stabilize for a few 
hours. Repeat the bleeding procedure when 
the tiny bubbles in the system have disap- 
peared. 



• Add brake fluid to proper level. 



ik WARN I IMG 



Check the operation of the brake after blee- 
ding the brake system. 



WB000009 

DRIVE CHAIN SLACK ADJUSTMENT 
Drive chain slack check: 

1. Measure: 

• Drive chain slack (D 

At the position shown in the photograph. 

Out of specification -» Adjust. 



Drive chain slack measurement steps: 

• Elevate the rear wheels by placing a suitab- 
le stand under the engine. 

• Rotate the rear wheel several times. 

• Check the chain slack several times to find 
the point where the chain is the tightest. 



Check the chain slack when the wheel is in 
this "tight chain" position. 




Drive chain slack (a) : 

30~40mmd.18~1.57in) 



• If the slack exceeds the limit 40mm(1 .6in), 
adjust the chain slack. 



3-28 



DRIVE CHAIN SLACK ADJUSTMENT 



INSP 


ra 


ADJ 




Drive chain slack adjustment: 

1 . Adjust: 

• Drive chain slack 

a************************************ 

Drive chain slack adjustment steps: 

• Loosen the rear wheel hub upper bolts (D . 

• Loosen the rear wheel hub lower bolts <D - 

• Loosen the adjuster locknut (3) . 

• Adjust chain slack by turning the adjuster 



To tighten -» Turn adjuster (4) clockwise. 



To loosen -> 

Turn adjuster (|) counter clockwise and 

push wheel forward. 



Turn each adjuster exactly the same 
amount to maintain correct axle alignment. 
(There are marks © on each side of chain 
puller alignment.) 



OAMTICHSi: 

Excessive chain slack will overload the 
engine and other vital parts;keep the slack 
within the specified limits. 

• If the chain slack cannot be adjusted, repla- 
ce the sprockets and drive chain as a set. 

• Tighten the rear wheel hub bolt and lock- 
nut. 



\ 


Rear wheel hub lower bolt: 


50 Nm (5.0 m • kg , 36 ft • lb) 




Rear wheel hub upper bolt: 




100 Nm (10 m- kg ,72 ft- lb) 




Locknuts(Chain puller) 




16 Nm (1.6 m- kg ,11 ft- lb) 



3-29 



DRIVE CHAIN LUBRICATION/ 
FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 



INSP 


wi 


ADJ 



NOTE: 

The chain should be cleaned and lubricated 
after every use of the machine. 



WB2A4025 

DRIVE CHAIN LUBRICATION 

The chain consists of many parts which 
work against each other. If the chain is not 
maintained properly, it will wear out rapidly, 
therefore, form the habit of periodically ser- 
vicing the chain. This service is especially ne- 
cessary when riding in dusty conditions. 
This motorcycle has a drive chain with small 
rubber O-rings between the chain plates. 
Steam cleaning, high-pressure washes, and 
certain solvents can damage these O-rings. 
Use only kerosene to clean the drive chain. 
Wipe it dry, and thoroughly lubricate it with 
SAE 30 — 50W motor oil. Do not use any 
other lubricants on the drive chain. They 
may contain solvents that could damage the 
O-rings. 



jft 



Recommended lubricant: 
SAE 30 — 50 W Motor Oil or 
chain lubricants suitable 
for "O-ring" chains. 




i 



WB000010 

FRONT AND REAR SHOCK ABSORBER AD 

JUSTMENT 

Front shock absorber: 

Preload: 

1 .Adjust: 

• Spring preload 
Turn the adjuster <D to increase to or dec- 
rease the spring preload. 



3-30 



FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 



INSP 


m 


ADJ 



Turning (2) 
way 


Spring preload is increa- 
sed. 


Turning <D 
way 


Spring preload is decrea- 
sed. 



Adjuster position: 


Standard 


A 


Minimum 


A 


Maximum 


E 



Rear shock Absorber: 




AWARIMIIMG 



This shock absorber contains highly pres- 
surized nitrogen gas read and understand 
the following information before handling 
the shock absorber. The manufacture 
cannot be held responsible for property 
damage or personal injury that may result 
from improper handling. 

• Do not tamper with or attempt to open 
the cylinder assembly. 

• Do not subject shock absorber to an open 
flame or other high hear source. This may 
cause the unit to explode due to excessi- 
ve gas pressure. 

• Do not deform or damage the cylinder in 
any way. Cylinder damage will result in 
poor damping performance. 

Preload: 

1. Loosen: 
• Locknut (D 
2. Adjust: 

• Spring set length 

Turn the adjuster (2) to increase or decrea- 
se the spring preload. 
Use a Special wrench. 

(3) Decrease spring preload 

(4) Increase spring preload 



3-31 



FRONT AND REAR SHOCK ABSORBER ADJUSTMENT 



INSP 


ra 


ADJ 



& 


Standard spring length: 


*\ 


(Installed): 




228.5 mm (9.0 in) 




Minimum length 




(Installed): 




220.5 mm (8.7 in) 




Maximum length 




(Installed): 




235.5 mm (9.3 in) 



NOTE: — 

One complete turn of the adjuster will 
change the preload 1.5mm(0.06in). Make 
changes in increments of 3mm<0.12in) at a 
time. 



<**itlON: _ 

Never attempt to turn the adjuster beyond 
the maximum or minimum setting. 



3. Tighten: 
• Locknut 




Locknut: 
54 Nm (5.4 m • kg,39 ft * lb) 



ms _ 

Always tighten the locknut against the 
spring adjuster and torque the locknut to 
specification. 



3-32 



BRAKE AND CHANGE PEDAL/BRAKE AND CLUTCH LEVERS 
LUBRICATION/CABLE INSPECTION AND LUBRICATION 



INSP 


e*a 


ADJ 




Damping: 

1. Adjust: 

• Damping 
Turn the adjuster ® to increase (D or dec- 
rease (D the damping. 



STD SETTING: 


15 clicks out 


MINIMUM SETTING: 


20 clicks out 


MAXIMUM SETTING 


: clicks out 



(D Match marks 

iHiiHiHii 

Never attempt to turn the adjuster beyond 
the maximum or minimum setting. 



WB000011 

BRAKE AND CHANGE PEDAL/BRAKE AND 
CLUTCH LEVERS LUBRICATION 

Lubricate pivoting peats of each lever and 
pedal. 




SAE 10W30 Motor oil 



WB000012 

CABLE INSPECTION AND LUBRICATION 

Cable inspection and lubrication steps: 

• Remove the two grip end that secure throt- 
tle to handlebar. 

• Hold cable end high and apply several 
drops of lubricant to cable. 

• Coat metal surface to disassembled thrott- 
le twist grip with suitable all-purpose 
grease to minimize friction. 

• Check for damage to cable insulation. Rep- 
lace any corroded or obstructed cables. 

• Lubricate any cables that do not operate 
smoothly. 



§ 



SAE 10W30 Motor oil 



•*****************•*•******##*****•** 



3-33 



STEERING AND SUSPENSION LUBRICATION/ 
WHEEL BEARINGS/STEERING SYSTEM 



INSP 


m 


ADJ 





WB0O0013 

STEERING AND SUSPENSION LUBRICA 
TION 

1. Lubricate: 

• Steering shaft lower bearing (D 

• Upper arm pivot (D 

• Lower arm pivot (D 

• Connecting rod pivot(Upper) (D 

• Relay arm pivot(lower) (5) 

• Relay arm pivot © 
Use a grease gun. 



S 



Lithium base grease 



WBOOOOU 

WHEEL BEARINGS 

1. Check: 

• Bearing movement 
Roughness -* Replace bearings. 

Raise the wheels and spin the wheel by 
hand. Check wheel movement and vibra- 
tion while spinning the wheel. 
Roughness/Excessive vibration -» Replace 
bearings. 

WB000015 

STEERING SYSTEM 

1. Check 

• Steering shaft radial play (D 
Radial play -> Replace upper bearing 

• Steering shaft thrust play © 
Thrust play -» Replace lower bearing 



2. Check: 

• Steering knuckle ball joints 

• Tie-rod ball joints 

Place the machine on a level surface and 
turn the handlebar quickly left and right. 
Looseness between handlebar and tires -» 
Check ball joints and replace faulty joints. 



3-34 




\E 




'/////////////////, 



TOE-IN ADJUSTMENT 



INSP 


WA 


ADJ 



WB000016 

TOE-IN ADJUSTMENT 

1 . Place the machine on a level surface. 

2. Measure: 
• Toe-in 

Out of specification -> Adjust. 



Toe-in measurement steps. 

• Mark both front tire tread centers. 

• Raise the front end of the machine so that 
there is no weight on the front tires. 

• Fix the handlebar straight ahead. 

• Measure the width El between the marks. 



Rotate the front tires 180 degrees until the 
marks come exactly opposite. 
Measure the width [B] between the marks. 
Calculate the toe-in using the formula 
given below. 



Toe-in 



Zl 




Toe-in: 

17 ~ 27mm{0.67 ~ 1.06in) 



• If the toe-in is incorrect, adjust the toe-in. 

************************************* 



3. Adjust: 
• Toe-in 



Adjustment steps: 

• Mark both tie-rods. 
This reference point will be needed during 
adjustment. 



3-35 



TOE-IN ADJUSTMENT/TIRE INSPECTION 



INSP 


Wd 


ADJ 




of 



• Loosen the locknuts(tie-rod end) (D 
both tie-rods. 

• The same number of turns should be given 
to both tie-rods <D right and left until the 
specified toe-in is obtained, so that the len- 
gths of the rods will be kept the same. 

• Tighten the rod end locknuts of both tie- 
rods. 




Locknut(rod end): 
30 Nm (3.0 m 



kg, 22 ft * lb) 



AWARNING 



• Be sure that both tie-rods are turned the 
same amount. If not, the machine will drift 
right or left even though the handlebar is 
positioned straight which may lead to mi- 
shandling and accident. 

• After setting the toe-in to specification, 
run the machine slowly for same distance 
with hands placed lightly on the handlebar 
and check that the handlebar responds 
correctly. If not, turn either the right or 
left tie-rod within the toe-in specification. 



WB000017 

TIRE INSPECTION 



AWARNING 



This model is equipped with low pressure 
tires. It is important that they be inflated 
correctly and maintained at the proper pres- 
sures. 

TIRE CHARACTERISTICS: 
• Tire characteristics influence the handling 
of ATV's. The tires listed below have 
been approved by Yamaha Motor Co.,Ltd. 
for this model. If other tire combinations 
are used, they can adversely affect your 
machine's handling characteristics and 
are therefore not recommended. 



3-36 



TIRE INSPECTION 



INSP 


m 


ADJ 





Manufac- 
ture 


Size 


Type 


Font 


Dunlop 


AT21X7- 
10 


KT764A 


Rear 


Dunlop 


AT22X10- 
9 


KT775 



TIRE PRESSURE: 

• Recommend tire pressure 

Front 30 kpa (0.30 kg/cm 2 , 4.4 psi) 
Rear 25 kpa (0.25 kg/cm 2 , 3.6 psi) 

• Tire pressure below the minimum speci- 
fied could cause the tire to dislodge from 
the rim under severe riding conditions. 
The following are minimum: 

Front 27 kpa (0.27 kg/cm 2 , 3.9 psi) 
Rear 22 kpa (0.22 kg/cm 2 , 3.2 psi) 

• Use no more then 

Front 250 kpa (2.5 kg/cm 2 , 36 psi) 
Rear 190 kpa (1.9 kg/cm 2 , 27 psi) 
When seating the tire beads. Higher pres- 
sures may cause the tire to burst. 
Inflate the tiers very slowly and carefully. 
Fast inflation could cause the tire to burst. 



1. Measure: 

• Tire pressure(cold tire pressure) 
Out of specification -» Adjust. 




NOTE: 

The low-pressure tire gauge (D is included 
in the standard equipment. 
If dust or the like is stuck to this gauge, it 
dose two measurements on the tire pres- 
sure and get the second reading. 



3-37 



TIRE INSPECTION 



INSP 


09 


ADJ 



cold tire 


Front 


K03T 


pressure 






Standard 


30kpa 


25kpa 




(0.3kg/cm z , 


(0.25kg/cm 2 , 




4.3psi) 


3.6psi) 


Minimum 


27kpa 


22kpa 




(0.27kg/cm z , 


(0.22kg/cm 2 , 




3.9psi) 


3.2psi) 




Maximum 


33kpa 


28kpa 




(0.33kg/cm 2 , 


(0.28kg/cm 2 , 




4.7psi) 


4.0psi) 




AWARMING 



Uneven or improper tire pressure may adver- 
sely affect the handling of this machine and 
may cause loss of control. 

• Maintain proper tire pressures. 

* Set pressures must be equal in both front 
tires and equal in both rear tires. 



2. Inspect: 
• Tire surfaces 
Wear/Damage -> Replace. 




Tire wear limit (D : 
Front and rear:3.0 mm(0.12 in) 



A WARN I IMG 



It is dangerous to ride with a wornout tire. 
When a tire wear is out of specification, rep- 
lace the tire immediately. 



3-38 



WHEEL INSPECTION/BATTERY INSPECTION 



WB2A3016 

WHEEL INSPECTION 

1. Inspect: 
• Wheels 

Damage/Bends-»Replace. 
NOTE: 



INSP 


pa 


ADJ 









/T) 


H 




® 










— 


+ 


^ 








367 000 



Always balance the wheel when a tire or 
wheel has been changed or replaced. 



^WARNING 



• Never attempt even small repairs to the 
wheel. 

• Ride conservatively after installing a tire 
to allow it to seat itself properly on the 
rim. 



WB202000 

ELACTRICAL 

BATTERY INSPECTION 

1. Inspect: 
• Fluid level 

Fluid level should be between upper (D 

and lower (D level marks. 

lncorrect-»Refill. 



CAUTION; 



Refill with distilled water only; tap water 
contains minerals harmful to a battery. 



2. Inspect: 

• Battery terminal 

Dirty terminal-»Clean with wire brush. 

Poor connection-»Correct. 

NOTE: 

After cleaning the terminals, apply grease li- 
ghtly to the terminals. 



3-39 



BATTERY INSPECTION 



INSP 


09 


ADJ 




3. Inspect: 

• Breather hose 

Obstruction->Remove. 

Damage-»Replace. 



liiiiiiiHiii 

When inspecting the battery, be sure the 
breather hose is routed correctly. If the 
breather hose touches the frame or exits in 
such a way as to cause battery electrolyte 
or gas to exit onto the frame, structural and 
cosmetic damage to the motorcycle can 
occur. 

4. Connect: 
• Breather hose 

Be sure the hose is properly attached and 

routed. 





5. Check: 
• Specific gravity 
Less than 1 ,280-»Recharge battery. 



Charging current: 
1.2 amps/ 10 hrs 

Specific gravity: 

1.280 at 20°C(68°F) 



ft************************************ 

Replace the battery if: 

• Battery voltage will not rise to a specific 
value or bubbles fail to rise even after 
many hours of charging. 

• Sulfation of one or more cells occurs, as in- 
dicated by the plates turning white, or an 
accumulation of material exists in the 
bottom of the cell. 

• Specific gravity readings after a long, slow 
charge indicate one cell to be lower than 
the rest. 

• Warpage or buckling of plates or insulators 
is evident. 

Always charge a new battery before using 
it to ensure maximum performance. 



3-40 



BATTERY INSPECTION/FUSE INSPECTION 



INSP 


09 


ADJ 



^WARNING 



Battery electrolyte is dangerous; it contains 
sulfuric acid and therefore is poisonous and 
highly caustic. 
Always follow these preventive measures: 

• Avoid bodily contact with electrolyte as it 
can cause severe bums or permanent eye 
injury. 

• Wear protective eye gear when handling 
or working near batteries. 

Antidote (EXTERNAL): 

• SKIN — Flush with water. 

• EYES — Flush with water for 15 minutes 
and get immediate medical attention. 

Antidote (INTERNAL): 

• Drink large quantities of water or milk 
follow with milk of magnesia, beaten egg, 
or vegetable oil. Get immediate medical at- 
tention. 

Batteries also generate explosive hydrogen 
gas, therefore you should always follow 
these preventive measures: 

• Charge batteries in a well— ventilated area. 

• Keep batteries away from fire, sparks, or 
open flames (e.g., welding equipment, ligh- 
ted cigarettes, etc.) 

• DO NOT SMOKE When charging or hand- 
ling batteries. 

KEEP BATTERIES AND ELECTROLYTE OUT 
OF REACH OF CHILDREN. 



WB302001 

FUSE INSPECTION 



caution: 

Don't forget to turn off the main switch 
when checking or replacing the fuse. Other- 
wise, it may cause accidental short-circui- 
ting. 



3-41 



FUSE INSPECTION 



INSP 


pa 


ADJ 





The fuse box is located under the left side 
rear fender. 
1. Inspect: 
• Fuses 



Description 


Amperage 


Quantity 


(I)Main 


15A 


1 


(D Reserve 


15A 


1 



************************************* 

Inspection steps: 

• Connect the pocket tester to the fuse and 
check it for continuity. 

NOTE: — 

Set the tester selector to "QXT position. 



P 



Pocket tester: 
P/NYU-03112 



• If the tester indicates infinity, replace the 

fuse. 

************************************* 



2. Replace: 

• Blown fuse 

************************************* 

Replacement steps: 

• Turn off the ignition. 

• Install a new fuse of proper amperage. 

• Turn on the switches to verify operation 
of electrical device. 

• If the fuse blows immediately again, check 

electrical circuit. 

************************************* 



AWARIMING 



Never use a fuse with a rating other then 
specified, or other, material in place of a 
fuse. An improper fuse may cause damage 
to the electrical system and possible cause 
a fire, or the lighting and/or ignition may 
cease to function. 



3-42 



HEADLIGHT BEAM ADJUSTMENT/ 
HEADLIGHT BULB REPLACEMENT 



INSP 


P9 


ADJ 



WB203001 

HEADLIGHT BEAM ADJUSTMENT 
1 . Adjust 

• Headlight beam (vertical) 
Turn the adjuster (D in or out. 




Turning in 


Headlight beam moves to 
upper. 


Turning 
out 


Headlight beam moves to 
lower. 



WB203003 

HEADLIGHT BULB REPLACEMENT 

1. Remove: 

• Headlight unit assembly 



2. Remove: 

• Bulb holder (f) 

Turn the bulb holder counterclockwise to 
release bulb. 

• Headlight bulb 

3. Install: 

• Bulb(New) 



^WARNING 



Keep flammable products and your hands 
away from the bulb while it is on, it will be 
hot. Do not touch the bulb until it cools 
down. 



3-43 



HEADLIGHT BULB REPLACEMENT 



INSP 


09 


ADJ 



caution: 

Avoid touching glass part of bulb. Also 
keep it free from oil otherwise, transparen- 
cy of glass, bulb life and illuminous flux 
will be adversely affected. If oil gets on 
bulb, clean it with a cloth moistened 
thoroughly with alcohol or lacquer thinner. 



3-44 



ENGINE REMOVAL 



ENG 





ENGINE OVERHAUL 

ENGINE REMOVAL 



NOTE: 

It is not necessary to remove the engine in order 

to remove the following components: 

•Piston 

•Clutch 

•Carburetor 

•AC magneto 



ENGINE OIL 

1. Drain: 
•Crankcase 
Refer to the "ENGINE OIL REPLACEMENT" 
section in the CHAPTER 3. 




SEAT, HEADLIGHT UNIT AND FUEL TANK 

1. Remove: 
•Seat 

• Headlight unit assembly 

• Front fender 
•Fuel tank 

Refer to the "VALVE CLEARANCE AD- 
JUSTMENT" section in the CHAPTER 3. 




CARBURETOR 

1. Loosen: 

•Carburetor joint nuts © 
•Air cleaner joint clamp screw 



4-1 



ENGINE REMOVAL 





2. Remove: 

• Carburetor cover (j) 



ENG 


^ 

wB 



3. Disconnect: 
•Throttle cable ® 

4. Remove: 
•Carburetor 



CLUTCH CABLE 

1. Loosen: 

•Locknut (T) 

2. Disconnect: 
•Clutch cable (2) 

NOTE: 



Loosen the clutch lever side adjuster. 
•Clutch cable holder (3) 

EXHAUST PIPE AND MUFFLER 

1. Remove: 

•Exhaust pipe © 
•Muffler (2) 



4-2 



ENGINE REMOVAL 



ENG 


** 




DRIVE SELECT LEVER AND CRANKCASE 
VENTILATION HOSE 

1. Remove: 

• Drive select lever assembly © 



2. Remove: 

• Crankcase ventilation hose © 



DRIVE CHAIN SPROCKET 

1. Remove: 

♦ Drive chain sprocket cover © 



2. Remove: 
•Nut © 

•Lock washer © 
• Drive chain sprocket 



FOOTRESTS 

1. Remove: 

•Footrest cover (left) © 



4-3 



ENG 






ENGINE REMOVAL 



2. Remove: 
•Bolt © 
• Left footrest and shift pedal assembly 

3) Match mark 



3. Remove: 

•Footrest cover (Right) © 



4. Remove: 

•Right footrest and brake pedal assembly © 



5. Remove: 

•Front fender stay © 



LEADS 

1. Disconnect: 

• Starter motor lead © 



4-4 



ENGINE REMOVAL 



ENG 






2. Disconnect: 

•Ground lead (T) 

• Reverse switch lead (2) 



3. Disconnect: 

• CDI Magneto leads 
•Neutral switch lead (T) 



ENGINE REMOVAL 

1. Remove: 

•Upper mounting bolts (T) 
•Front mounting bolt (2) 
•Rear upper mounting bolt (J 
•Rear lower mounting bolt ® 
•Engine assembly 



4-5 



ENGINE DISASSEMBLY 



ENG 


•4 



ENGINE DISASSEMBLY 

DECOMPRESSION CAM, CAM CHAIN 
SPROCKET AND CYLINDER HEAD 
NOTE: 

With the engine mounted, decompression cam, 
cam chain sprocket and cylinder head can be 
maintained by removing the following parts. 

• Fuel tank 

•Engine stays (upper) 
•Carburetor 

• Exhaust pipe 




1. Remove: 
•Spark plug 
•Timing window plug (T) 




2. Remove: 

♦Cylinder head side cover ® 
•O-rings 



3. Remove: 

• Intake valve cover 
•O-ring 

• Exhaust valve cover (J) 



4-6 



ENGINE DISASSEMBLY 



ENG 


%» 




4. Remove: 

•Left crankcase cover 



5. Turn: 

• Crankshaft 

6. Align: 

• Flywheel "T" mark 

(with the stationary pointer 0, when piston 
is at TDC on compression stroke.) 



NOTE: 

TDC on Compression Stroke Check: 
•Both rocker arms must have a valve clearance 
when the cam chain sprocket mark is aligned 
with the cylinder head mark (2). 
•If not, give the crankshaft one counterclock- 
wise turn to meet the above condition. 



7. Remove: 

•Timing chain tensioner 



4-7 



ENGINE DISASSEMBLY 



ENG 






8. Remove: 

•Sprocket bolts 
•Washer 
•Sprockets (T) 
NOTE: 



Fasten safety wire (2) to the cam chain to pre- 
vent it from falling into the crankcase. 



NOTE: 

If difficult to loosen the cam sprocket securing 
bolts; hold the starter pulley ©. 



9. Remove: 

•Cylinder head 
NOTE: 



Loosen the bolts in their proper loosening se- 
quence. Number means loosening sequence. 



10. Remove: 

•Cylinder head gasket (J) 
•Dowels (2) 

•Exhaust side cam chain guide 
•O-ring (4) 



CYLINDER AND PISTON 

1. Remove: 
•Bolt (T) 
•Cylinder 



4-8 



ENGINE DISASSEMBLY 



ENG 






Remove: 

• Cylinder gasket (j) 

• Dowels (|) 

• O-ring @ 



Remove: 

• Piston pin circlips (j) 



4. Remove: 
•Piston pin © 
• Piston @ 
NOTE: 



•Before removing the piston pin clip, cover the 
crankcase with a clean rag so you will not ac- 
cidentally drop the clip into the crankcase. 

•Before removing the piston pin, deburr the clip 
groove and pin hole area. If the piston pin groove 
is deburred and piston pin is still difficult to re- 
move, use Piston Pin Puller. 



]U. 



Piston pin puller: 
P/N. YU-01304 



CAUTION: 



Do not use a hammer to drive the piston pin 
out. 

LEFT CRANKCASE COVER AND CDI 

MAGNETO 

NOTE: 

With the engine mounted, the starter clutch, 
starter idle gear and CDI magneto can be main- 
tained by removing the following parts. 
•Shift lever 



4-9 



ENGINE DISASSEMBLY 



ENG 





\. 





1. Remove: 
•Bolt 

•Spring washer 
♦ Plain washer 
•Starter pulley (j) 
•O-ring (2) 



2. Remove: 

• Left crankcase cover 



3. Remove: 

• Dowels (T) 
•Gasket (2) 



4. Remove: 
•Bracket (T) 
•Source coil (2) 
•Pick up coil (3 



4-10 



ENGINE DISASSEMBLY 



ENG 






5. Remove: 

• Collar © 
•Shaft (2) 

• Idle gear i 



6. Remove: 

• CDI magneto (4) 
NOTE: 



When removing the CDI magneto, use the 
flywheel puller ©. 







Flywheel puller: 
P/N. YM-01404 



7. Remove: 

•Woodruff key (§) 

• Driven gear (Starter) (7) 

• Bearing (8) 
•Washer (9) 




CAM CHAIN AND STARTER MOTOR 

1. Remove: 

• Intake side chain guide (T) 

• Cam chain (2) 



2. Remove: 

• Starter motor (T) 



4-11 



ENGINE DISASSEMBLY 




ENG 


%m 



OIL FILTER AND NEUTRAL SWITCH 

1. Remove: 

•Oil filter cover (T) 
•O-ring @ 
•Oil filter (§) 







2. Disconnect: 

• Neutral switch lead © 

3. Remove: 
•Neutral switch (2) 






k* j*^ 




RIGHT CRANKCASE COVER 

1. Remove: 

•Right crankcase cover 



2. Remove: 

•Circlip (T) 
•Washer (2) 
•Pinion gear (3) 
•Push lever axle (4) 
•Short push rod (5) 




3. Remove: 

• Gasket © 

• Dowels (5) 



4-12 



ENGINE DISASSEMBLY 



ENG 





CLUTCH 
NOTE: _ 



With the engine mounted, the clutch assembly, 
primary drive gear and balancer driven gear can 
be maintained by removing the following parts: 
•Starter motor 
•Crankcase cover {right) 




sNuJ" - ® 



*i . ic* © 



Remove: 

• Long push rod (T) 

• Bearing (2) 

• Clutch spring holding screws 
•Pressure plate 2 (4) 
•Clutch springs (§) 

•Nut © 
•Washer (7) 

• Clutch boss (8) 

• Friction plates (9) 
•Clutch plates® 
•Cushion springs ® 
•Pressure plate 1 © 
•Thrust washer @ 
•Clutch housing @ 
•Spacer ® 




NOTE: 



Loosen the nut (clutch boss} while holding the 
clutch boss with the rotor holder. 



n 



Rotor holder: 
P/N. YU-01235 



4-13 



ENGINE DISASSEMBLY 



ENG 






PRIMARY DRIVE GEAR AND BALANCER 
DRIVEN GEAR 

1. Remove: 
•Nut ® 

•Lock washer (2) 
•Washer (3) 

• Primary drive gear (4) 

• Balancer drive gear assembly (§) 
•Key ® 

•Oil pump drive gear (7) 

•Key® 

•Nut (|) 

• Lock washer ® 

• Balancer driven gear © 

• Key® 



NOTE: 

Place a piece of rolled rag (T) or lead between 
gears when loosening balancer driven gear @ 
and primary drive gear (3). 



OIL PUMP 

1. Remove: 

• Screws 

•Oil pump assembly (T) 

• Gasket 




2. Remove: 

•Housing connecting screws (T) 
•Oil pump housing (2) 

• Outer rotor (3) 

• Inner rotor (4) 
•Pin (D 

•Oil pump shaft (6) 



4-14 



ENGINE DISASSEMBLY 




ENG 


%m 



SHIFT SHAFT 

1. Remove: 
•Shift shaft ® 
•Washer (2) 
•Bolt (3) 
•Stopper (4) 
•Stopper spring 




OIL PIPE 

1. Remove: 
• Union bolts 
♦Washers 
•Oil pipe (T) 



CRANKCASE 

1. Remove: 

•Crankcase holding screws 
(from left crankcase) 



NOTE: 

•Remove the reverse shift cam bolt (j), washer 
(2), spring ® and ball ® before separating 
crankcase. 

•Loosen each screw 1/4 turn, and remove them 
after all are loosened. 



2. Remove: 

• Right crankcase 
NOTE: 



As pressure is applied, alternately tap on the 
balancer shaft, main axle, and shift cam. 



4-15 



ENGINE DISASSEMBLY 



ENG 






3. Remove: 
• Dowels (J) 



4. Remove: 

• Reverse axle assembly 
•Counter axle assembly (2) 



5. Remove: 
•Washer (T) 
•Reverse pinion gear 
•Circlip (3) 
• Reverse axle (4) 




6. Remove: 
•Washer (J) 
• Counter wheel gear 
•Washer (J) 
•Counter axle (3) 




7. Remove: 
• Guide bar © 
(from the shift fork of the out put axle) 



4-16 



ENGINE DISASSEMBLY 



ENG 


*-• 



(D-^ 




(D (D(D 



8. Remove: 
•Collar 

•Out put axle (j), shift fork (2), and shift cam 
(3) assembly 



9. Remove: 
•Circlips (T) 
•Washer © 

•Forward wheel gear (3) 
•Dog clutch (4) 

• Circlip © 
•Washer (6) 
•Reverse wheel gear (7) 
•Out put axle (§) 
•O-ring (f) 
•Collar® 

•Guide bar © 
•Shift fork© 

• Shift cam <J$ 




10. Remove: 

•Guide bars ® 
(from the shift forks of the main and drive 
axles) 



11. Remove: 

• Shift cam assembly (j) 

• Shift fork "C" © 
•Shift fork "L" (3) 

• Shift fork "R" (4) 



4-17 



ENGINE DISASSEMBLY 





ENG 


*-• 



12. Remove: 

•Drive axle © and main axle (2) assembly 



13. Remove: 
•Washer © 

•Counter axle drive gear (2) 
•1st wheel gear ® 
•5th wheel gear (4) 
{from the drive axle) 




14. Remove: 
•Circlip © 
•Washer @ 
•2nd wheel gear (3) 
•6th wheel gear (4) 
•Circlip © 
•Washer (6) 
•4th wheel gear (7) 
•3rd wheel gear (8) 
• Drive axle (9) 



15. Remove: 

•Balancer shaft © 



4-18 



ENGINE DISASSEMBLY 



ENG 






16. Remove: 

• Crankshaft 

***************************************** 

Removal steps: 

• Attach the crankcase separating tool (T) and 
attachment (2) to the left side crankcase. 



f> 



Crankcase separating tool: 

P/N. YU-01135 
Attachment: 

P/N. YM-1382 



NOTE: 

Fully tighten the tool holding bolts, but make sure 
the tool body is parallel with the case. If neces- 
sary, one screw may be backed out slightly to lev- 
el tool body. 

^^m.^************************* ************ 

BEARINGS AND OIL SEALS 

NOTE: — 

•It is not necessary to remove bearings and oil 

seals unless damaged. See Bearings and oil seals 

(INSPECTION AND REPAIR.) 
•To facilitate bearing removal and installation, first 

heat the cases to approximately 95°~125°C 

(205° ~257°F) using an oven. Bring the case up 

to proper temperature slowly. 

1. Remove: 
•Oil seals 

CAUTION: 



•Use a screwdriver to pry out the seal. 
•Place a piece of wood under the screw- 
driver to prevent damage to the case. 

2. Remove: 
• Bearings 



4-19 



ENGINE DISASSEMBLY 



ENG 





CRANKSHAFT/ROCKER ARMS/VALVES 
NOTE: . 

With the engine mounted, the camshaft, rocker 

arms and valves can be maintained by removing 

the following parts: 

•Fuel tank 

•Engine stay {upper) 

•Exhaust pipe 




Straighten: 

• Lock washer tabs (J) 

Remove: 

•Lock washer (2) 

•Retainer (camshaft bearing) 




3. Remove: 
•Camshaft (T) 
•Camshaft bearing 
NOTE: 



Screw in a suitable bolt (3) into the thread of the 
camshaft, and pull out the camshaft. 



4. Remove: 

• Rocker arm shafts (T) 
•Rocker arms (intake/exhaust) 
Use the slide hammer (2). 



m 



Slide hammer set: 
P/N. YU-01083 



4-20 



ENGINE DISASSEMBLY 




ENG 





5. Check: 

•Valve sealing 

Leakage at valve seat -»• Inspect the valve 

face, valve seat and valve seat width. 

Refer to "INSPECTION AND REPAIR - 

VALVE SEAT". 

NOTE: 

Before removing the internal parts (valve, valve 
spring, valve seat etc.) of the cylinder head, the 
valve sealing should be checked. 

***************************************** 
Valve seat checking steps: 

• Pour a clean solvent (T) into the intake and ex- 
haust ports. 

• Check the valve seating. 

There should be no leakage at the valve seat 

©■ 

***************************************** 



6. Remove: 

•Valve cotters (J) 
•Spring retainer (2) 
• Valve spring (inner) (3) 
•Valve spring (outer) (4) 
•Oil seal (5) 
•Spring seat (§) 
•Valve (7) 













® 










L-f-T_HC TO 










J 











NOTE: 

Remove the valve cotters while compressing the 
valve springs with the valve spring compressor 



m 



Valve spring compressor: 
P/N. YM-04019 



4-21 



INSPECTION AND REPAIR 




ENG 





INSPECTION AND REPAIR 

CYLINDER HEAD 

1. Eliminate: 

•Carbon deposit 
{from combustion chamber) 
Use rounded scraper (T). 
NOTE: 



Do not use a sharp instrument and avoid damag- 
ing or scratching: 
•Spark plug threads 
•Valve seat 



2. Inspect: 

•Cylinder head 
Scratches/ Damage 



Replace. 





J 


f- "r^4 












i tfj 


\ r-pd?*>7 






o 


\2^§M 


lyk^Jj 












lof 




3. Measure: 
•Warpage 
Out of specification -* Resurface. 




S 



Cylinder head warpage: 

Less than 0.03 mm (0.0012 in) 



4. Resurface: 

•Cylinder head 

***************************************** 

Resurfacement steps: 

Place a 400-600 grit wet sandpaper on the sur- 
face plate, and resurface the head using a figure- 
eight sanding pattern. 

NOTE: 

Rotate the head several times to avoid removing 
too much material from one side. 



***************************************** 



4-22 



INSPECTION AND REPAIR 



ENG 





VALVE SEAT 

1. Eliminate: 
•Carbon deposit 

(from valve face and valve seat) 

2. Inspect: 
•Valve seat 

Pitting/ Wear->Reface the valve seat. 






C\ 


) /rj 




"~ 302-01/ 



3. Measure: 

•Valve seat width ® 
Out of specification ->Ref ace valve seat. 



fit 


Valve seat width: 


-*-\ 


Intake: 




0.9-1.1 mm (0.035-0.043 in) 




Exhaust 




0.9-1.1 mm (0.035-0.043 in) 



Measurement steps: 

• Apply the Mechanic's bluing dye (Dykem) (j) 
to the valve face. 

• Install the valve into the cylinder head. 

• Press the valve through the valve guide and 
onto the valve seat to make a clear pattern. 

• Measure the valve seat width. Wherever the 
valve seat and valve face made contact, blu- 
ing will have been removed. 

• If the valve seat width is too wide, too narrow, 
or seat has not centered, the valve seat must 
be refaced. 

**********#*****************##**■*******■** 




4. Reface: 
•Valve seat 
Use a 20°, 45° and 60° Valve Seat Cutter 



n 



Valve seat cutter: 
P/N. YM-91043 



CAUTION: 



When twisting cutter, keep an even down- 
ward pressure (4-5 kg) to prevent chatter 
marks. 



4-23 



D 



INSPECTION AND REPAIR 



ENG 









Cut sections as follows 


Section 


Cutter 


A 


20° 


B 


45° 


C 


60° 



Refacing steps: 

El Valve face indicates that valve seat is cen- 
tered on valve face but is too wide. 



Valve seat cutter set 


Desired result 


Use 
lightly 


20° cutter 


To reduce valve 
seat width to 
1.0 mm (0.039 in). 


60° cutter 



H] Valve seat is in the middle of the valve 
face but too narrow. 



Valve seat cutter set 


Desired result 


Use 


45° cutter 


To achieve a 
uniform valve seat 
width of 1.0 mm 
(0.039 in). 



[C] Valve seat is too narrow and right up near 
valve margin. 



Valve seat cutter set 


Desired result 


Use 


20° cutter, 
first 


To center the seat 
and to achieve its 
width of 1.0 mm 
(0.039 in). 


45° cutter 



[D] Valve seat is too narrow and is located 
down near the bottom edge of the valve 
face. 



Valve seat cutter set 


Desired result 


Use 


60° cutter, 
first 


To center the seat 
and increase 
its width. 


45° cutter 



#********#*****#**#*****#**#*#*####*###*# 



4-24 



INSPECTION AND REPAIR 



ENG 





5. Lap: 

•Valve face 
•Valve seat 
NOTE: 



After refacing the valve seat or replacing the valve 
and valve guide, the valve seat and valve face 
should be lapped. 






2=^ 




Lapping steps: 

• Apply a coarse lapping compound to the valve 
face. 

CAUTION: 

Be sure no compound enters the gap be- 
tween the valve stem and guide. 

• Apply a molybdenum disulfide oil to the valve 
stem. 

• Install the valve into the cylinder head. 

• Turn the valve until the valve face and valve 
seat are evenly polished, then clean off all 
compound. 

NOTE: 

To obtain the best lapping results, lightly tap the 
valve seat while rotating the valve back and forth 
between your hands. 



• Apply a fine lapping compound to the valve 
face and repeat the above steps. 

NOTE: 

Be sure to clean off all compound from the valve 
face and valve seat after every lapping operation. 

• Apply the Mechanic's bluing dye (Dykem) to 
the valve face. 

• Install the valve into the cylinder head. 

• Press the valve through the valve guide and 
onto the valve seat to make a clear pattern. 

• Measure the valve seat width again. 

If the valve seat width is out of specification, 
reface and lap the valve seat. 



4-25 



INSPECTION AND REPAIR 



ENG 






VALVE/VALVE GUIDE 

1. Measure: 

• Stem-to-guide clearance 



Stem-to-guide clearance = 
Valve guide inside diameter @ 
Valve stem diameter (b) 



Out of specifications Replace valve guide. 



& 


Stem-to-guide clearance: 


*~\ 


Intake 0.010-0.037 mm 




(0.0004-0.0014 in) 




< Limit: 0.06 mm (0.002 in)> 




Exhaust 0.030-0.057 mm 




(0.00120-0.00220 in) 




< Limit: 0.08 mm (0.003 in)> 



2. Replace: 

•Valve guide 

**********#***#****#*******#**##*.***#.)<.#*.if. 

Replacement steps: 

NOTE: 

Heat the cylinder head in an oven to 100°C 
(212°F) to ease guide removal and installation and 
to maintain correct interference fit. 

• Remove the valve guide using the Valve guide 
remover (J). 

• Install the valve guide (new) using the valve 
guide installer (2) and valve guide remover (T). 

• After installing the valve guide, bore the valve 
guide using the valve guide reamer (3) to ob- 
tain proper stem-to-guide clearance. 



&2* 


Valve guide remover: 


</ 


P/N YM-01225 




Valve guide installer: 




P/N YM-04017 




Valve guide reamer: 




P/N YM-01227 



NOTE: 

Reface the valve seat after replacing the valve 
guide. 



4-26 



INSPECTION AND REPAIR 



ENG 





3. Eliminate: 

• Carbon deposit (from valve face) 

4. Inspect: 
•Valve face 

Pitting/Wear-»Grind the face. 
•Valve stem end 
Mushroom shape or diameter larger than rest 
of stem -> Replace. 




h 

r 



/ / // 



77 




r 



7TTT7777TT 



» 



v;//// 



5. Measure: 

•Margin thickness (a) 
Out of specification -+ Replace. 



^ 


Margin thickness: 


^-\ 


Intake 




0.8-1.2 mm (0.031-0.047 in) 




Exhaust 




0.8-1.2 mm (0.031-0.047 in) 



6. Measure: 

• Runout (valve stem) 
Out of specification -"Replace. 




Runout: 

Less than 0.01 mm (0.0004 in) 



NOTE: 

•Always replace the guide if the valve is replaced. 
•Always replace the oil seal if the valve is 
removed. 



CAMSHAFT 

1. Inspect: 
• Cam lobes 
Pitting/Scratches/Blue discoloration 
-►Replace. 



4-27 



INSPECTION AND REPAIR 



ENG 







. ® . 








§D 


® Li I p^ 












/ 



2. Measure: 

•Cam lobes length (a) and (6). 
Out of specification-* Replace. 




A* 


Cam lobe length: 


^~\ 


Intake 




® 40.62-40.72 mm 




(1.599-1.603 In) 




® 32.18-32.28 mm 




(1.267-1.271 in) 




Exhaust 




® 40.62-40.72 mm 




(1.599-1.603 in) 




© 32.18-32.28 mm 




(1.267-1.271 in) 



ROCKER ARM/ROCKER ARM SHAFT 

1. Inspect: 
•Rocker arm shaft 

Blue discoloration/ Grooves-* Replace, then 
inspect lubrication system. 

2. inspect: 

• Bore (rocker arm shaft) (T) 

•Cam lobe contact surface (2) 

•Adjuster surface (3) 
Wear/ Pitting/ Scratches/ Blue discoloration 
-* Replace, then inspect lubrication system. 



3. Measure: 

•Arm-to-shaft clearance 
Out of specification ~+ Replace as a set. 



Arm-to-shaft clearance = 

Bore size (rocker arm shaft) @ - 

Outside diameter (rocker arm shaft) (E 







, © 


/ \ 








J 


M3 j&m 





& 


Arm-to-shaft clearance: 


^\ 


0.009-0.037 mm 




(0.0003-0.0015 in) 




< Limit: 0.10 mm (0.004 in)> 



4-28 



INSPECTION AND REPAIR 



ENG 


*— 




VALVE SPRING 

1. Measure: 

•Free length (a) (valve spring) 
Out of specification - Replace. 




fl 



Free length (valve spring): 
Inner spring 

39.9 mm (1.57 in) 
Outer spring 

43.27 mm (1.70 in) 



2. Measure: 

•Compressed force @ (valve spring) 
Out of specification -> Replace. 

(6) Installed length 



& 


Compressed force (valve spring): 


^\ 


Inner spring 




10.7-12.3 kg at 33.6 mm 




(23.59-27.12 lb at 1.323 in) 




Outer spring 




24.0-25.6 kg at 36.6 mm 




(52.91 -56.44 lb at 1.441 in) 




3. Measure: 
• Spring tilt @ 
Out of specification-* Replace. 




Spring tilt: 
Inner spring 

1.6 mm (0.063 in) 
Outer spring 

1.6 mm (0.063 in) 



TIMING CHAIN/CHAIN GUIDE/SPROCKET 

1. Inspect: 

•Timimg chain 
Stiff/ Cracks^ Replace timing chain and 
sprocket as a set. 



4-29 



INSPECTION AND REPAIR 



ENG 


%» 




2. Inspect: 
•Sprocket 
Wear/ Damage-* Replace sprocket and tim- 
ing chain as a set. 

CD 1/4 tooth 

(2) Correct 

(D Roller 

® Sprocket 



3. Inspect: 

•Chain guide ® (exhaust side) 
•Chain guide (2) (intake side) 
Wear/ Damage-* Replace. 



CYLINDER/PISTON 

1. Eliminate: 
•Carbon deposits 

(from the piston crown and ring grooves) 

2. Inspect: 
•Piston wall 

Wear/ Scratches/ Damage-* Replace. 



3. Eliminate: 

• Score marks and lacquer deposits 
From the sides of piston. 
Use a 600-800 grit wet sandpaper. 

NOTE: 

Sand in a crisscross pattern. Do not sand exces- 
sively. 



4. Inspect: 
• Cylinder wall 
Wear/ Scratches-* Rebore or replace. 



4-30 



INSPECTION AND REPAIR 



ENG 







5. Measure: 

• Piston-to-cylinder clearance 

Piston-to-cylinder clearance measurement 
steps: 



First steps 



• Measure the cylinder bore "C" with a cylinder 

bore gauge. 
(a) 40 mm (1.57 in) from the cylinder top 

NOTE: 

Measure the cylinder bore "C" in parallel to and 

at right angles to the crankshaft. 

Then, find the average of the measurements. 




Cylinder Bore "C": 
82.97-83.02 mm 
(3.267-3.269 in) 
< Limit: 83.10 mm (3.272 in)> 




• If out of the specification, rebore or replace the 
cylinder, and the piston and piston rings as a 
set. 



2nd steps 



• Measure the piston skirt diameter "?" with a 

micrometer. 
(b) 4 mm (0.16 in) from the piston bottom edge 




Piston skirt diameter "P": 
82.04-82.05 mm 
(3.2299-3.2303 in) 



• If out of the specification, replace the piston 
and piston rings as a set. 



3rd steps | 
• Find the piston-to-cylinder clearance with fol- 



lowing formula. 



Piston-to-cylinder clearance 
Cylinder bore "C"- 
Piston skirt diameter "P" 




Piston-to-cylinder clearance: 
0.040-0.060 mm 
(0.0016-0.0024 in) 
< Limit: 0.15 mm (0.006 in)> 



4-31 



INSPECTION AND REPAIR 



ENG 





• If out of the specification, rebore or replace the 
cylinder, and replace the piston and piston rings 
as a set. 




PISTON RING 

1. Measure: 
•Side clearance 
Out of specification 
rings as a set. 
NOTE: 



■Replace piston, and 



Eliminate carbon deposit from piston ring grooves 
and rings before measuring side clearance. 




fs 


Side clearance: 


*~\ 


Top ring 




0.04-0.08 mm 




(0.0016-0.0031 in) 




2nd ring 




0.03-0.07 mm 




(0.0012-0.0028 in) 



2. Position: 

•Piston ring (into the cylinder) 
NOTE: 



Push the ring with the piston crown so that the 
ring will be at a right angle to cylinder bore. 



(a) : 20 mm (0.8 in) 



3. Measure: 
•Eng gap 
Out of specification 
NOTE: 



•Replace. 



You cannot measure end gap on expander spacer 
of oil control ring. If oil control ring rails show ex- 
cessive gap, replace all three rings. 



4-32 



INSPECTION AND REPAIR 



ENG 






End Gap: 

Top ring 

0.20-0.40 mm 
(0.008-0.016 in) 

2nd ring 

0.20-0.40 mm 
{0.008-0.016 in) 

Oil ring 

0.30-0.90 mm 
(0.012-0.036 in) 



PISTON PIN 

1. Inspect: 
•Piston pin 
Blue discoloration/Grooves 
inspect lubrication system. 



Replace, then 




® 


f2P 


w 


307-020 



2. Measure: 

•Outside diameter ® (piston pin): 
Out of specification -"Replace. 




Outside diameter (piston pin): 
18.990-18.995 mm (0.75 in) 



3. Measure: 

• Piston pin-to-piston clearance 
Out of specification-* Replace piston. 



Piston pin-to-piston clearance = 
Bore size (piston pin) ® - 
Outside diameter (piston pin) @ 




Piston pin-to-piston clearance: 
0.014-0.02 mm 
(0.0006-0.0008 in) 
< Limit: 0.07 mm (0.003 in)> 



4-33 



INSPECTION AND REPAIR 




ENG 





r=r© 


q 


® 


® 


5 


— 1 


PI 


IY 


-sr 1 - 1 


j 


\ 


n 








P 


_ „ 






-O 




" ® ' " 



CRANKSHAFT/CONNECTING ROD 

1. Measure: 

•Crank width ® 
Out of specification -"Replace crankshaft. 




Crank width: 
58.95-59.00 mm 
(2.321-2.323 in) 



•Runout® 
Out of specification ^Replace crankshaft 
and/or bearing. 




Runout: 

Less than 0.06 mm (0.002 in) 



•Small end free play © 
Out of specification -"Replace big end bear- 
ing, crank pin and/or connecting rod. 




Small end free play: 

0.8-1.0 mm (0.031-0.039 in) 



•Side clearance @ 
Out of specification -» Replace connecting 
rod. 



^ 


Big end side clearance: 


*~\ 


0.35-0.85 mm 




(0.014-0.033 in) 



ELECTRIC STARTER DRIVES 

1. Inspect: 

•Roller (J) operation 
Unsmooth operation -"Replace one-way 
clutch. 



Replacement points: 

• Tighten the bolts to specification. 



K 



Bolts (starter clutch): (f) 
30 Nm (3.0 m.kg, 22 ft. lb) 
Apply LOCTITE® 



• Calk the end of the bolts using a punch. 



4-34 



INSPECTION AND REPAIR 



ENG 


%m 




2. Inspect: 

•Starter wheel gear teeth ® 
• Idle gear teeth (2) 
Burrs/Chips/ Roughness/ Wear-> Replace. 



3. Inspect: 

• Contacting surfaces 
Pitting/Wear/ Damage-* Replace. 



4. Check: 

•Starter clutch operation 

************************ ***************** 

Clutch operation checking steps: 

• Install the starter wheel gear to the starter 
clutch, and hold the starter clutch. 

• When turning the wheel gear clockwise ®, 
the starter clutch and the wheel gear should be 
engaged. 

If not, the starter clutch is faulty. Replace it. 

• When turning the wheel gear counterclockwise 
(2), the wheel gear should turn freely. 

If not, the starter clutch is faulty. Replace it. 
***************************************** 
PRIMARY DRIVE 
1. Inspect: 

♦ Primary drive gear (T) 

• Primary driven gear (2) 

Wear/ Damage^ Replace both gears. 
Excessive noises during operation ^-Replace 
both gears. 



Primary reduction ratio: 


No. of teeth 


Ratio 


Drive ] Driven 


24 | 76 


3.167 



4-35 



INSPECTION AND REPAIR 





ENG 


wB 



CLUTCH 

1. Inspect: 
•Friction plate 
Damage/ Wear-* Replace friction plate as a 
set. 



2. Measure: 

• Friction plate thickness 
Out of specification ~> Replace friction plate 
as a set. 
Measure at all four points. 




Thickness: 

2.94-3.06 mm (0.116-0.120 in) 
< Limit: 2.8 mm (0.11 in)> 



3. Inspect: 
•Clutch plate 
Damage -► Replace clutch plate as a set. 



4. Measure: 

•Clutch plate warpage 
Out of specification-* Replace clutch plate 
as a set. 
Use a surface plate and feeler gauge (T). 




H 



Warp limit: 

Less than 0.2 mm (0.008 in) 



5. Inspect: 
•Clutch spring 
Damage-* Replace as a set. 



4-36 



INSPECTION AND REPAIR 



ENG 


\m 





d> 



6. Measere: 

•Clutch spring free length 
Out of specification -► Replace spring as a 
set. 




Free length (clutch spring): 
47.8 mm {1.88 in) 
< Limit: 46.5 mm (1.83 in)> 



7. Inspect: 

•Clutch housing dogs 
Cracks/ Pitting (edges): 
Moderate-* Deburr. 
Severe-" Replace clutch housing. 
NOTE: 



Pitting on friction plate dogs of clutch housing 
will cause erratic operation. 

8. Inspect: 

•Clutch housing bearing 
Damage-* Replace. 

9. Inspect: 

•Clutch boss spline 
Pitting: 

Moderate-^ Deburr. 
Severe-* Replace. 
NOTE: 

Pitting on clutch plate splines of clutch boss will 
cause erratic operation. 

10. Inspect: 

• Pressure plate 1 © 

• Pressure plate 2 (2) 
•Bearing (3) 
•Long push rod (4) 

Damage-" Replace. 




11. Measure: 

•Cushion spring height (T) 
Out of specification-* Replace. 




fl 



Cushion spring height: 

3.3±0.15 mm (0.128±0.0059 in) 



4-37 



INSPECTION AND REPAIR 




m^® 



ENG 





12. Inspect: 

• Push lever axle (j) 
•Short push rod (2) 

• Pinion gear ® 
Damage-* Replace 





OIL PUMP 

1. Measure: 

• Side clearance (a) 
Use a feeler gauge 
Out of specification 

sembly. 



Replace oil pump as- 



& 


Side clearance: 


^-\ 


0.04-0.09 mm (0.002-0.004 in) 




<Limit>: 




0.09 mm (0.004 in) 



2. Measure: 

•Tip clearance (a) 
Use a feeler gauge. 

Out of specification-* Replace oil pump as- 
sembly. 



sx 


Tip clearance: 


<*-N 


0.0-0.15 mm (0.0-0.006 in) 




< Limit >: 




0.20 mm (0.008 in) 



3. Inspect: 



• Oil pump drive gear teeth (j) 
•Oil pump driven gear teeth (2) 
Wear/Cracks/ Damage-* Replace. 




SHIFTER 

1. Inspect: 

•Shift return spring © 

Damage-* Replace. 
•Shift shaft (f) 

Damage/ Bends/ Wear-* Replace. 



4-38 



INSPECTION AND REPAIR 



ENG 


Tffll 




2. Inspect: 
• Shift forks 
On the gear and shift cam contact surfaces. 
Wear/Chafing/Bends/ Damage-* Replace. 



3. Measure: 

•Runout (guide bar) 
Out of specification-* Replace. 




Runout: 
Less than 0.8 mm (0.032 in) 



A WARNING 



Do not attempt to straighten a bent guide 
bar. 

4. Check: 

• Shift fork movement 
On its guide bar ©. 

Unsmooth operation-* Replace fork and/or 
guide bar. 



5. Inspect: 

•Shift cam grooves (J) 

Wear/ Damage/Scratches-* Replace. 
•Shift cam segment (2) 

Damage/ Wear-* Replace. 
• Shift cam bearing (§) 

Roughness/Sluggishness-* Replace. 



TRANSMISSION 

1. Measure: 

•Axle runout (main and drive axles) (T) 
Use centering device and Dial Gauge (2). 
Out of specification-* Replace. 




Runout: 

Less than 0.08 mm (0.0031 in) 



4-39 



INSPECTION AND REPAIR 



ENG 


\m 



2. Inspect: 
•Gear teeth 

Blue discoloration/ Pitting/ Wear-* Replace. 
•Mating dogs 

Rounded edges/ Cracks/ Missing portions-* 

Replace. 




3. Check: 

•Gear movement (transmission) 
Unsmooth operation -» Repair. 




# * 



•01® 



<2> (I) 



BALANCER DRIVE GEAR 

1. Inspect: 

•Balancer drive gear (J) 
•Boss (2) 
•Pins (3) 
•Springs (4) 
•Washers (5) 
Damage/ Wear/ Fatigue-* Replace. 




2. Align: 

• Boss match mark (T) 
(with the drive gear mark @) 
NOTE: 



Be sure to install a pin (3) to every other spring. 



CRANKCASE 

1. Inspect: 

• Case halves 

• Bearing seat 
•Fitting 

Damage-* Replace. 



4-40 



INSPECTION AND REPAIR 



ENG 


*<• 




BEARINGS AND OIL SEALS 

1. Inspect: 
• Bearing 

Clean and lubricate, then rotate inner race 

with finger. 

Roughness-* Replace bearing 

(see Removal). 

2. Inspect: 
•Oil seals 

Damage/Wear-> Replace (see Removal). 



4-41 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


wB 










V- — J 










ENGINE ASSEMBLY AND 
ADJUSTMENT 

CAMSHAFT/ROCKER ARMS/VALVES 

1. Deburr: 

•Valve stem end 
Use an oil stone to smooth the stem end. 



2. 


Apply: 










•High-Quality molybdf 


snum 


disulfide motor oil 




(to the valve stem and oi 


I seal.) 


3. 


Install: 
•Valve (T) 
•Spring seat 
•Oil seal (3) 


© 








•Valve spring 


(inner) 


® 






•Valve spring 


(outer) 


© 






•Spring retainer © 








•Valve cotter 


(7) 






WOTF- 









All valve springs must be installed with the larg- 
er pitch (a) upward as shown. 



NOTE: 

Compress the valve spring with the valve, spring 
compressor (8) and then, install the valve cotters. 



Jt 



Valve spring compressor: 
P/N YM-04019 



Apply: 
•Engine oil 

(to the bearing of the camshaft) 
•High-Quality molybdenum disulfide motor oil 

(to the rocker arm and shaft) 
Install: 

• Camshaft (T) 

• Camshaft bearing (2) 
•Rocker arm ® 

• Rocker arm shaft (4) 



4-42 



ENGINE ASSEMBLY AND ADJUSTMENT 



Install: 

•Rocker arms (T) 

•O-ring @ 

• Rocker arm shafts 
•Camshaft (4) 
•Stopper plate © 

• Lock washer © 
•Bolts (7) 



NOTE: 



ENG 


4. 

1» 




•Insert the rocker arm shaft into the rocker arm 

through the cam chain cavity. 
•Inside thread (T) face cam chain cavity. 
•Install the O-rings © on the rocker arm shafts. 
•Be sure the camshaft pin © faces upward. 
•The stopper plate tab (4) should be bent along 

the bolt flat. 



4-43 



ENGINE ASSEMBLY AND ADJUSTMENT 



ROCKER ARM, AND 

© Adjuster locknut 
(D Adjuster 
(D Rocker arm 
(4) Valve retainer 
© Spring seat 
© Oil seal 
Inner spring 
(D Outer spring 
(§) Valve 



CAMSHAFT 


($ Circlip 

(Q) Valve guide 

@ Rocker arm shaft 


@ O-ring 
@ Camshaft 
@ Stopper plate 
© Lock washer 



© Bearing 



ENG 





| 20 Nm {2.0 m»kg, 14 ft. lb) 



<D 




A 


VALVE SPRING FREE LENGTH: 


B 


OUTER: 43.27 mm (1.70 in) 


C 


INNER: 39.9 mm (1.57 In) 



D 


VALVE CLEARANCE 
(COLD): 


E 


INTAKE: 
0.06-0.10 mm 
(0.00236-0.00394 in) 


F 


EXHAUST: 
0.16-0.20 mm 
(0.00630-0.00787 in) 



8 Nm (0.8 m.kg, 5.8 ft. lb) 



4-44 



ENGINE ASSEMBLY AND ADJUSTMENT 




ENG 


^§9 



TRANSMISSION/BALANCER/CRANK 
SHAFT 

1. Install: 
•Crankshaft 
(into the left crankcase) 



$* 


Crankshaft installer set (J): 


</ 


P/N YU-90050 




Adapter (2): 




P/N YM-1383 




Spacer (3): 




P/N YM-91044 



CAUTION: 



To protect the crankshaft against scratches 
or to facilitate the operation of the installa- 
tion, apply the engine oil to each bearing. 



NOTE: 

•Be sure the connecting rod @ is in cylinder 
sleeve hole (5). 




2. Install: 

• Balancer shaft 
NOTE: 



Be sure the thread (J) side face upward. 



3. Install: 

• Drive axle (T) and main axle (2) assembly 






ENGINE ASSEMBLY AND ADJUSTMENT 



4. Install: 

• Shift fork "C" © 
•Shift fork "L" (2) 

• Shift fork "R" (3) 

• Shift cam assembly (4) 

NOTE: 



ENG 


1SB 




•Mesh the shift fork "L" with the 6th wheel gear 

and "R" with the 5th wheel gear on the drive 

axle, 
•Mesh the shift fork "C" with the 3rd/4th pinion 

gear on the main axle. 
• Install the shift forks with the embossed letters 

should face upward. 




5. Install: 

• Guide bars (T) 



6. Check: 

• Shifter operation 
Unsmooth operation -> Repair. 



7. Install: 

•Output axle (T), shift fork 

(3) assembly 
•Collar 



), and shift cam 



4-46 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 






8. Install: 

• Guide bar © 
(into the shift fork of the output axle) 



9. Install: 

• Reverse axle assembly (J) 
•Counter axle assembly (2) 

NOTE: 



•Insert the counter axle cutting side (3) into the 

crankcase. 
•The small cutside diameter gear (4) must face 

to counter axle cutting side. 



4-47 



ENGINE ASSEMBLY AND ADJUSTMENT 



CRANKSHAFT AND BALANCER SHAFT 



(T) Balancer driven gear 

(D Bearing 

(D Straight key 

(?) Balancer shaft 

(D Washer 

(D Balancer drive gear 

(7) Boss 



(0) 



Woodruff key 
Crank: Right: 
Connecting rod 
Big-end bearing 
Crank pin 
Crank: Left: 



ENG 





CRANKSHAFT RUNOUT: 



® 58.95-59.00 mm 
(2.321 -2.323 in) 
0.35-0.85 mm 
(0.014-0.033 in) 
0.06 mm (0.002 in) 
0.8-1.0 mm 
(0.031-0.039 in) 





50 Nm (5.0 m.kg, 36 ft*lb) 



B PISTON RING END GAP (INSTALLED): 


TOP RING 

AND 
2ND RING 


0.20-0.40 mm 
(0.008-0.016 in) 


OIL RING 


0.30-0.90 mm (0.012-0.036 in) 



4-48 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


Is* 



TRANSMISSION AND SHIFTER 

Transmission 

CD Bearing (Q) 

@ Reverse axle (52) 

(I) Circlip @ 

(4) Reverse pinion gear (34T) (0) 

© Plain washer @ 

© Drive sprocket (J§) 

(7) Oil seal © 

(D Collar ® 

(D O-ring @ 
® Output axle 



Reverse wheel gear (33T) 

Dog clutch 

Forward wheel gear (29T) 

Counter axle HOT) 

Counter wheel gear (20T/14T) 

2nd wheel gear (33T) 

6th wheel gear (23T) 

4th wheel gear (27T) 

3rd wheel gear (29T) 

5th wheel gear (25T) 



@> Drive axle 

@ 1st wheel gear (36T) 

@> Counter axle drive gear (27T) 

@ 2nd pinion gear (20T) 

® 6th pinion gear (29T) 

® 3rd/4th pinion gear (23T/26T) 

@ 5th pinion gear {28T) 

® Main axle (1st pinion gear: 16T) 




4-49 



ENGINE ASSEMBLY AND ADJUSTMENT 

Shifter 

(D Output axle shift cam 

(D Output axle shift fork 

® Output axle guide bar 

® Shift fork "R" 

© Shift fork "C" 

© Shift fork "L" 

(7) Guide bar 

(D Shift shaft 

(D Shift cam assembly 

@ Stopper 



ENG 





10 Nm {1.0 m.kg, 7.2 ft«lb) 




10 Nm (1.0 m.kg, 7.2 ft. lb) 



14 Nm (1.4 m.kg, 10 ft. lb) 
LOCTITE® 



4-50 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 







CRANKCASE 

1. Apply: 
• Sealant 
(to matching surface of both case halves) 



p 



Sealant (Quick Gasket®): 

ACC-11001-05-01 
Yamaha Bond IMo.4: 

90890-05143 



2. Install: 
•Dowel pins (J) 

3. Fit the right crankcase onto the left case. 
Tap lightly on the case with a soft hammer. 

CAUTION: 

Before installing and torquing the crankcase 
holding screws, be sure to check whether 
the transmission is functioning properly by 
manually rotating the shift cam either way. 

4. Tighten: 

• Screws (crankcase) 

NOTE: 

Tighten the bolts starting with the lowest num- 
bered one. 



\ 



Screws (crankcase): 

10 Nm (1.0 m-kg, 7.2 ft. lb) 



5. Apply: 
•4-stroke engine oil 

To the crank pin, bearing and oil delivery 
hole. 

6. Check: 

•Crankshaft and transmission operation 
Unsmooth operation -► Repair. 




7. Install: 
•Ball © 
•Spring (2) 
•Washer (§) 
• Reverse shift cam bolt (4) 



\ 



Reverse shift cam bolt: 
10 Nm (1.0 m.kg, 7.2 ft. lb) 



4-51 



ENGINE ASSEMBLY AND ADJUSTMENT 



EIMG 


^ 
%+ 




NOTE: 



Install the clamp ® on screw No. 8. 



OIL PIPE 

1. Install: 
•Washers 
•Oil pipe (J) 
•Union bolts 



\ 



Union bolts: 
16 l\lm (1.6 m.kg, 11 ft-lb) 



SHIFT SHAFT 

1. Install: 

•Stopper spring (J) 
•Stopper (2) 
•Bolt ® 
•Washer (4) 
•Shift shaft (5) 



K 



Stopper bolt: 

14 IMm {1.4 m.kg, 10 ft. lb) 




NOTE: ___ 

•Mesh the stopper lever roller (T) with the seg- 
ment cam (2). 
• Insert the stopper pin (3) between shift shaft 
springs (4). 



4-52 



ENGINE ASSEMBLY AND ADJUSTMENT 



OIL PUMP 

1. Install: 

•Oil pump shaft © 

•Pin @ 

• Inner rotor © 

•Outer rotor (4) 

•Oil pump housing © 

•Housing connecting screw 



ENG 







K 



Housing connecting screw: 
7 Nm (0.7 m-kg, 5.1 ft»lb) 



•Gasket 

NOTE: 

Align the inner rotor mark © with the outer ro- 
tor mark (2) in the pump housing ©. 
Then insert the pump shaft into the inner rotor. 

2. Install: 

•Oil pump assembly © 



\ 



Oil pump screw: 

7 Nm (0.7 m-kg, 5.1 ft-lb) 



BALANCER DRIVEN GEAR AND PRIMARY 
DRIVE GEAR 

1. Install: 
•Key © 

• Balancer driven gear (2) 

• Lock washer (3) 
•Nut @ 

•Key © 

•Oil pump drive gear © 

•Key® 

•Balancer drive gear assembly © 

•Primary drive gear © 

♦Washer © 

•Lock washer © 

♦Nut® 



4-53 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 






NOTE: 

Align the balancer drive gear mark © with the 
balancer driven gear mark (5). 



2. Tighten: 

•Primary drive gear securing nut © 
•Balancer driven gear securing nut (; 



K 



Primary drive gear nut: 
80 Nm (8.0 m.kg, 58 ft. lb) 

Balancer driven gear nut: 
60 Nm (6.0 m.kg, 43 ft-lb) 



NOTE: 

Place a piece of rolled rag @ or lead between 
gears when loosening balancer driven gear (2) 
and primary drive gear ©. 




CLUTCH 

1. Install: 
•Spacer © 
•Clutch housing (2) 
•Thrust washer @ 

• Pressure plate 1 (4) 
•Cushion springs (5) 
•Clutch plates (6) 
•Friction plates (7) 
•Clutch boss (8) 
•Washer (9) 
•Nut® 

• Clutch springs ® 

• Pressure plate 2 © 
•Clutch spring holding screws 
•Bearing @ 

•Long push rod © 



4-54 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


^§9 





NOTE: 

•Be sure the cushion springs (T) is installed un- 
der the 3rd and 5th friction plates {narrow one 
(2)) from the clutch boss ® side. 



►Align the pressure plate 1 arrow mark (j) with 
the clutch boss arrow mark (2). 



•Align the friction plate mark (T) with the 
clutch housing marks @. 



►Tighten clutch boss securing nut (J) using ro- 
tor holding tool (2) {YU-01235). 



\ 



Clutch boss nut: 

80 IMm (8.0 m-kg, 58 ft-lb) 



•Tighten clutch spring holding screws. 



\ 



Clutch spring screw: 

10 Nm (1.0 m-kg, 7.2 ft*lb) 



4-55 



ENGINE ASSEMBLY AND ADJUSTMENT 



CLUTCH 

Op Push lever 
(2) Push lever axle 
(D Short push rod 
@ Pinion gear 
(!) Long push rod 
® O-ring 

(7) Pressure plate 2 
(D Clutch spring 



(9) Clutch boss 
® Cushion spring 
(0) Clutch plate 
@ Friction plate 
(Q) Pressure plate 
@ Clutch housing 
© Primary drive gear 
© key 



ENG 





10 Nm {1.0 m.kg, 7.2 ft-lb) 



CLUTCH SPRING FREE LENGTH 
LIMIT: 
46.5 mm (1.831 in) 



FRICTION PLATE WEAR LIMIT: 
2.8 mm (0.110 in) 



CLUTCH PLATE WARP LIMIT: 
0.2 mm (0.00787 in) 




80 Nm (8.0 m.kg, 58 



4-56 



ENG 





ENGINE ASSEMBLY AND ADJUSTMENT 



RIGHT CRANKCASE COVER 

1. Install: 

• Short push rod (j) 
•Push lever axle (2) 
•Pinion gear (J) 
•Washer (J) 
•Circlip (5) 



NOTE: 

Align the punch mark (J) on the push lever with 
the center of ribs (2), (3) on the crankcase. 






2. Install: 

• Gasket © 

• Dowels (2) 



3. Install: 

• Right crankcase cover 



\ 



Right crankcase cover screw: 
10 Nm (1.0 m. kg, 7.2 ft-lb) 



NEUTRAL SWITCH AND OIL FILTER 

1. Install: 
•Neutral switch 
• Neutral switch lead (2) 




Neutral switch: 
20 Nm (2.0 m.kg, 14 ft-lb) 



4-57 



ENGINE ASSEMBLY AND ADJUSTMENT 



2. Install: 
•Oil filter (§) 
•O-ring (2) 
• Oil filter cover 




ENG 





K 



K 



Oil filter cover hexagon bolt: 
10 Nm (1.0 m-kg, 7.2 ft. lb) 



STARTER MOTOR AND CAM CHAIN 

1. Install: 
•O-ring © 
•Starter motor (2) 



K 



Starter motor bolt: 

10 Nm (1.0 m-kg, 7.2 ft-lb) 




2. Install: 

•Cam chain (T) 

•Intake side chain guide (2) 



\ 



Intake side chain guide bolt: 
10 Nm (1.0 m.kg, 7.2 ft-lb) 



CDI MAGNETO AND LEFT CRANKCASE 

1. Install: 

•Idler gear (T) 

• Shaft © 

• Collar (3) 
•Washer (4) 
•Bearing (5) 
•Gear (6) 
•Key (7) 
•CDI rotor (8) 



4-58 



ENGINE ASSEMBLY AND ADJUSTMENT 



2. Install: 

• Pick up coil (J) 

• Source coil (2) 

• Bracket (3) 




ENG 





X 



Source/Pick up coil screws: 
10 Nm {1.0 rn-kg, 7.2 ft^b) 




3. Install: 
• Dowels (T) 
•Gasket (2) 



4. Install: 

• Left crankcase cover 



X 



\ 



Left crankcase cover bolts: 
10 Nm (1.0 m.kg, 7.2 ft. lb) 



5. Install: 
•O-ring (J) 
•Starter pully (f) 
•Plain washer 
•Spring washer 
•Bolt 



r^ 



Flywheel magneto bolt: 
50 IMm (5.0 m.kg, 36 ft-lb) 



6. Install: 

• Left crankcase cover 



K 



Crankcase cover bolt: 

10 Nm (1.0 m.kg, 7.2 ft-lb) 



4-59 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 






CYLINDER HEAD/CYLINDER/PISTON 

1. Install: 
•Piston ® 
•Piston pin (2) 
•Piston pin clips (3) (new) 
NOTE: 

•The arrow on the piston must point to the front 

of the engine. 
•Before installing the piston pin clip, cover the 

crankcase with a clean towel or rag so you will 

not accidentally drop the pin clip and material 

into the crankcase. 



2. Apply: 

•4~stroke engine oil 

To the piston pin, piston ring grooves and 
piston skirt areas. 




3. Install: 

•Cylinder gasket ® 
•Dowels (2) 
•O-rings (§) 



4. Install: 
•O-ring ® 
(onto cylinder sleeve) 



4-60 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 





CD, 




\v 25 °A 


\^°// 





i® 




4. Offset the piston ring end gaps as shown. 



NOTE: 



•Be sure to check the manufacturer's marks or 
numbers stamped on the rings are on the top 
side of the rings, 

•Before installing the cylinder, apply a liberal coat- 
ing of 4-stroke engine oil to the piston rings. 



(T) Top ring 

(2) Oil ring (Lower rail) 

(5) 2nd ring 

(4) Oil ring (Upper rail) 

5. Install: 
• Cylinder ® 
•Bolts (cylinder) 
Temporary tighten 
NOTE: 



• Install the cylinder with one hand while com- 
pressing the piston rings with the other hand. 

•Fasten a safety wire @ to the timing chain, and 
pass the timing chain through the chain cavity. 

6. Install: 
•Bolt (T) 



Cylinder securing bolt: 

10 Nm (1.0 m.kg, 7.2 ft. lb) 



Install: 

•Chain guide (exhaust) (T) 

•0~ring (2) 

•Dowel pins (3) 

•Gasket (new) (4) 



4-61 



ENGINE ASSEMBLY AND ADJUSTMENT 



PISTON AND CYLINDER 

(T) Cylinder 

(2) O-ring (New) 

® Cylinder gasket (New) 

(§) Dowel 

S O-rtng (New) 
Top ring 
(?) 2nd ring 



(D Oil ring 

(9) Piston 

(0> Piston pin 

(Q) Piston pin clip (New) 

@ Oil ring (Lower rail) 

(Q) Oil ring (Upper rail) 



ENG 





SIDE CLEARANCE 
0.04-0.08 mm 
(0.0016-0.0031 in 



END GAP LIMIT (Installed) 
0.20-0.40 mm 
(0.008-0.016 in 






PISTON CLEARANCE: 


F 


0.040-0.060 mm 




(0.0016-0.0024 in) 



<E> 


I® 


/ 25° \j 


J/ 25° \ 


V 25° / 


k-V 25 / 


®^" 


^® 



4-62 



ENGINE ASSEMBLY AND ADJUSTMENT 



8. Install: 

•Cylinder head assembly (T) 
•Bolts (cylinder head) (2) 

NOTE: 




ENG 





Fasten a safety wire (3) to the timing chain (4) 
so that it may not drop into the crankcase. 



9. Tighten: 

•Bolts (cylinder head) 



X 


Flange bolt: 


40 Nm {4.0 nrkg, 29 ft*lb) 




Hexagon bolt: 




20 IMm {2.0 m.kg, 14 ft-lb) 



NOTE: 



Tighten the bolts starting with the lowest num- 
bered one. 




10. Install: 

• Cam sprocket 

Cam sprocket installing steps: 

• Rotate the camshaft to align the camshaft pin 
(T) with the cylinder head match mark (2). 

• Remove the timing plug. 

• Turn the starter pulley counterclockwise until 
the "T" mark (3) is aligned with the stationary 
pointer @ on the crankcase spacer. 

• Place the timing chain onto the cam sprocket. 

• Install the cam sprocket onto the camshaft, and 
finger tighten the sprocket bolt. 



4-63 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


*%— 





NOTE: - 

Be sure the match mark (5) on the cam sprock- 
et is aligned with the match mark (6) on the 
cylinder head. 



> Turn the camshaft clockwise and counterclock- 
wise to remove the timing chain slack. 
1 Insert your finger into the timing chain tensioner 
hole, and push the timing chain guide inward. 
While pushing the timing chain guide, make 
sure that cam sprocket match mark © is 
aligned with the cylinder head match mark (6). 
If marks is aligned, tighten the cam sprocket 
bolt. 



K 



Bolt (cam sprocket): 
60 Nm (6.0 m.kg, 43 ft. lb) 



NOTE: _ 

Tighten the bolt (cam sprocket} while holding the 
starter pulley ©. 



• If marks do not align, change the meshing 
position of sprocket and chain. 



11. Install: 

• Cam chain tensioner 

***********#**#***#***#####**.**##*.X-#**.*.*.»f. 

Cam chain tensioner installation steps: 

• Remove the tensioner end cap bolt and spring. 

• Release the cam chain tensioner one-way cam 

©• 

• Push the tension rod assembly (2) into the 
body. 

• Install the tensioner (3) with a new gasket (4) 
onto the cylinder. 

CAUTION: 



The one-way cam (§) should be faced 
downward. 



4-64 



ENGINE ASSEMBLY AND ADJUSTMENT 




EIMG 


^ 

«• 



\ 



Tensioner Body Bolts (§): 
10 Nm (1.0 irrkg, 7.2 ft*lb) 



• Install the spring (7), washer (8) and end cap 
bolt ©. 



\ 



Tensioner End Cap Bolt: 
38 Nm (3.8 m«kg, 27 ft • lb) 



#*##******#***■*#*******#****-***#********■* 

12. Adjust: 

•Valve clearance 
Refer to "VALVE CLEARANCE ADJUST- 
MENT" section in the CHAPTER 3. 




Intake valve (cold): 

0.06-0.10 mm 

(0.00236-0.00394 in) 
Exhaust valve (cold): 

0.16-0.20 mm 

(0.00630-0.00787 in) 



13. Install: 

•Crankcase cover (left) (T) 




14. Install: 

•Cam sprocket cover ® 
•Spark plug © 
•Tappet cover (3) (exhaust) 
•Tappet cover (4) (intake) 



\ 


Screws (Cam sprocket cover): 


10 Nm (1.0 m-kg, 7.2 ft. lb) 




Spark plug: 




17.5 Nm (1.75 nvkg, 12.5 ft-lb) 




Bolts (tappet covers): 




10 Nm (1.0 m.kg, 7.2 ft-lb) 



NOTE: 



•Apply lithium soap base grease to the Orings. 
•Install the tappet covers with its ridge facing 
upward. 



4-65 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 





CYLINDER HEAD AND CAM CHAIN 



SPROCKET 

(T) Intake valve cover 

® O-ring 

(3) Cam chain tensioner 

@ Gasket 

(5) Intake side cam chain guide 

(D Cylinder head side cover 

(7) Cam chain sprocket 



(8) Cam chain 

(9) Cylinder head gasket 
# O-ring 

(Q) Exhaust side cam chain guide 

§ Dowel 
Exhaust valve cover 



40 Nm (4.0 m.kg, 29 ft-lb) 



17.5 Nm 

(1.75 m.kg, 12.5 ft-lb) 



10 Nm (1.0 m-kg, 7.2 ft. lb) 



38 Nm (3.8 m.kg, 27 ft. lb) 



10 Nm (1.0 m.kg, 7.2 ft. lb) 




10 Nm (1.0 m.kg, 7.2 ft*lb) 



A TIGHTENING SEQUENCE 




m.kg, 7.2 ft. lb) 



60 Nm (6.0 m.kg, 43 ft. lb) 



CYLINDER HEAD 
WARP LIMIT: 
0.03 mm (0.0012 in) 



D 



SPARK PLUG: 



D8EA/X24ES-U 



GAP: 



0.6-0.7 mm 
(0.024-0.028 in) 



4-66 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 





REMOUNTING ENGINE 

Reverse the "ENGINE REMOVAL" procedure. 
Note the following points. 



AWARIMING 



Securely support the machine so there is no 
danger of it falling over. 




1. Install: 
•Engine assembly 

2. Install: 

•Engine stay (T) (front -upper) 
•Bolt (2) {front - lower) 
• Engine stay (3) {rear -upper) 
•Bolt (4) {rear -lower) 

NOTE: 



All mounting bolts should be installed from the 
right of the machine. 



\ 



Nuts (engine mounting bolts): 
33 Nm (3.3 m*kg, 24 ft « lb) 



3. Install: 

• Front fender stay (T) 



4. Install: 

•Footrest (T) (right) 
(with brake pedal, master cylinder and reser- 
voir tank as one unit) 



\ 


Bolts (footrest and frame) 


55 Nm (5.5 nvkg, 40 ft. lb) 




Bolts (master cylinder and frame) 




20 Nm (2.0 m-kg, 14 ft. lb) 



4-67 



ENGINE ASSEMBLY AND ADJUSTMENT 




ENG 





5. Install: 

• Footrest cover (right) (T) 



6. Install: 

•Footrest (T) (left) 
•Shift pedal assembly (2) 



\ 



Bolt (shift pedal): 

10 Nm (1.0 m.kg, 7.2 ft-lb) 
Bolts (footrest and frame): 

55 IMm (5.5 m.kg, 40 ft-lb) 



NOTE: _____ 

Align the opening (3) of the shift pedal with the 
mark (4) of the shift shaft. 




7. Install: 

•Footrest cover (left) © 



8. Install: 

•Drive chain sprocket © 
•Lock washer (2) 
•Nut © 



\ 



Drive chain sprocket nut: 
75 Nm (7.5 m.kg, 54 ft- lb) 



4-68 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 






9. Install: 

• Drive chain sprocket cover © 



\ 



Drive chain sprocket cover bolt: 
10 Nm (1.0 m.kg, 7.2 ft. lb) 



10. Install: 

•Crankcase ventilation hose (T) 



11. Install: 

•Drive select lever assembly (T) 



12. Install: 

•Exhaust pipe (T) 
•Muffler @ 



\ 


Bolts (exhaust pipe and cylinder): 


12 Nm (1.2 m.kg, 8.7 ft-lb) 




Bolts (clamp): 




20 Nm (2.0m. kg, 14 ft-lb) 




Bolts (muffler and frame): 




27 Nm (2.7 m-kg, 19 ft. lb) 



4-69 



ENGINE ASSEMBLY AND ADJUSTMENT 



ENG 


wB 



13. Adjust: 

•Clutch (release lever free play) 
Refer to the "CLUTCH ADJUSTMENT" 
section in the CHAPTER 3. 

14. Adjust: 

•Cable slack (parking brake cable) 
Refer to the "PARKING BRAKE ADJUST- 
MENT" section in the CHAPTER 3. 

15. Bleed: 
•Brake fluid 

Refer to the "AIR BLEEDING (HYDRAU- 
LIC BRAKE SYSTEM)" section in the 
CHAPTER 3. 

16. Fill: 
•Crankcase 

Refer to the "ENGINE OIL REPLACEMENT" 
section in the CHAPTER 3. 

17. Install. 

• Fuel tank 
♦Front fender 

• Headlight unit assembly 
•Seat 

Refer to the "VALVE CLEARANCE AD- 
JUSTMENT" section in the CHAPTER 3. 



4-70 



CARBURETOR 



CARB 


* 



CARBURETION 



CARBURETOR 

CD Carburetor cap 

S Spring 
Needle holder 

(4) Jet needle 

(5) Pilot screw 

(6) Piston valve 
@ Pilot jet 

(D Main nozzle 
(§) Main jet 
(K& Float 



Specifications 



(jj) Coasting enricher rubber 

diaphragm 
(g) Cover 

© Throttle stop screw 
(j3> Starter plunger assembly 
(Jjj) Valve seat assembly 
© Float pin 
© Drain screw 
0l> Accelerator plunger 



MAIN JET (M.J.) 


#145 


MAIN AIR JET (M.A.J.) 


00.6 


JET NEEDLE (J.N.) 


5J18-3 


PILOT JET (P.J.) 


#42.5 


PILOT AIR JET (P.A.J. 1) 


01.0 


(P.A.J. 2) 


00.7 


PILOT SCREW 


2 turns out 


FLOAT VALVE SEAT 


02.5 


ENGINE IDLE SPEED 


1,450-1,550 r/min 




**%/ 




c^ 



5-1 



CARBURETOR 



CARB 


* 



SECTION VIEW 

© Air 

(2) Mixture 

(D Fuel 

(4) Air inlet 

© Starter valve 

(§) Mixture outlet 

(?) Starter jet 

(D Starter bleed pipe 

(D Pilot air circuit 



© 






Pilot outlet 
Pilot screw 
Pilot jet 
Bypass hole 
Throttle valve 
Main jet 
Main nozzle 
Jet needle 
Main air jet 



f Piston valve 
Pilot air jet No. 1 
(3) Pilot air jet No. 2 
© Fuel joint 
@ Float 
® Needle valve 
(§) Valve seat 
(g> Diaphragm assembly 
07) Check valve 



@ Plunger 

COASTING ENRICHER SYSTEM 

1] MAIN & SLOW SYSTEM 

E FLOAT SYSTEM 

EI STARTER SYSTEM 

E ACCELERATION PUMP SYSTEM 




5-2 



CARBURETOR 



CARB 


4 




REMOVAL 

1. Remove: 
•Seat 



NOTE: . 

Pull the seat lever upward, and pull the seat. 



2. Turn the fuel cock to "OFF" ® position. 

3. Disconnect: 

• Fuel hose (2) 
(from the fuel cock) 



4. Loosen: 

•Drain screw © 
Drain the float chamber of its fuel. 



5. Loosen: 

• Screw (2) (clamp) 

6. Remove: 

•Nuts (3) (intake manifold) 




7. Remove: 

•Top cover (J) (with piston valve) 



5-3 




CARBURETOR 



CARB 


# 



8. Remove: 

• Rink cover (J) 

•Throttle cable (2) (throttle valve and 
plunger) 



DISASSEMBLY 
NOTE: 



The following parts can be cleaned and inspect- 
ed without disassembly. 
•Throttle stop screw 
• Pilot screw 




1. Disconnect: 
•Fuel hose (T) 
•Air ventilation hose (2) 



2. Remove: 

• Float chamber 
•Float pin (2) 

• Float (3) 
•Main nozzle (4) 
•Main jet (5) 

• Pilot screw (§) 
•Pilot jet (7) 

• Cover (|) 

•Coasting enricher rubber diaphragm 
•Throttle stop screw ® 
•Starter plunger assembly ® 
•Accelerator plunger © 
•Valve seat assembly © 
•Drain screw (0) 



5-4 



CARBURETOR 



CARB 


* 



mm 




3. Disconnect: 

•Throttle cable (j) 
(from the piston valve) 



NOTE: 

Disconnect the throttle cable while compressing 
the spring by hand. 



4. Remove: 

•Carburetor cap (j) 

• Spring (2) 
•Needle holder (3) 
•Jet needle @ 

• Piston valve (5) 



5. Remove: 

• Cover (j) 
•Spring (2) 

• Coasting enricher rubber diaphragm (3) 



**% 




6. Remove: 

• Float chamber cover © 
•O-ring (2) 



^^a-? 
<£-<?** 




7. Remove: 
•Spring (j) 

•Accelerator plunger (2) 
• Rubber cap (3) 



5-5 



CARBURETOR 



CARB 


* 




INSPECTION 

1. Inspect: 

• Carburetor body 
Crack/ Damage ~> Replace, 
Contamination-* Clean. 
NOTE: 



•Use a petroleum based solvent for cleaning. 
►Blow out all passages and jets with compressed 
air. 



2. Inspect: 
•Floats 
Damage 



Replace. 




3. Inspect: 

•Float needle valve ® 
•Seat @ 
•O-ring ® 
Damage/ Wear/ Contamination 
a set. 



Replace as 





4. Inspect: 

•Jet needle © 
Damage/Bends/Wear- 



Replace. 



■ 4 #&&L 




Inspect: 

• Starter plunger 
Wear/ Damage-* Replace. 



5-6 




CARBURETOR 



CARB 


* 



6. Inspect: 

•Coasting enricher rubber diaphragm (J) 
•Spring (2) 
•Cover (3) 
Damage/Tears (diaphragm) -* Replace. 



ST® 




7. Inspect: 
•Main jet (T) 
•Main nozzle (?) 
•Pilot jet (|) 

Contamination -► Blow out. 
•Pilot screw (4) 
•Spring © 
•O-ring (§) 

Damage-*- Replace. 



8. Inspect: 
• Piston valve 
Wear/ Damage 



Replace. 



Check: 

•Free movement 
Stick ~* Replace. 

Insert the throttle valve into the carburetor 
body, and check for free movement. 



ASSEMBLY 

Reverse the "DISASSEMBLY" procedures. Note 
the following points. 

CAUTION: 

Before reassembling, wash the all parts with 
clean gasoline. 

1. Tighten: 
•Pilot jet 
•Main jet 



\ 


Pilot jet: 

1 Nm (0.1 m.kg, 0.7 ft. lb) 




Main jet: 




1 Nm (0.1 m.kg, 0.7 ft-lb) 




Screws (float chamber): 




2 Nm (0.2 m.kg, 1.4 ft-lb) 




Screws (needle valve holder): 




1 Nm (0.1 m.kg, 0.7 ft. lb) 



5-7 



CARBURETOR 



CARB 


* 



2. Adjust: 
•Pilot screw 



Pilot screw: 
2 turns out 




INSTALLATION 

Reverse the "REMOVAL" procedures. Note the 

following points. 
1. Install: 

• Piston valve (2) (with jet needle} 
•Top cover (with throttle valve) 



\ 



Screw (top cover): 

2 Nm (0.2 m.kg, 1.4 ft. lb) 



2. Install: 

•Throttle cable (2) 

(throttle valve and plunger) 
• Rink cover ® 



^ 



\ 



Screws (rink cover): 

2 Nm (0.2 nrkg, 1.4 ft-lb) 



3. Install: 
• Carburetor 



V 



^ 



Nuts (intake manifold): 
10 Nm (1.0 m.kg, 7.2 ft. lb) 



4. Check: 
•Cables routing 
• Hoses routing 

Incorrect-* Correct. 

Refer to the "CABLE ROUTING" section in 

the CHAPTER 2. 

5. Check: 

•Throttle cable operation 
Unsmooth operation -► Repair. 



5-8 




Billi 



CARBURETOR 



CARB 


# 



6. Adjust: 

• Idle speed 
Refer to "IDLE SPEED ADJUSTMENT" 
section in the CHAPTER 3. 

7. Adjust: 

•Throttle cable free play 
Refer to "THROTTLE CABLE FREE PLAY 
ADJUSTMENT" section in the CHAPTER 3. 



FLOAT HEIGHT ADJUSTMENT 

NOTE: 

After the float, valve seat and needle valve are 
installed to the carbureter body, float height 
should be adjusted. 

1. Hold the carburetor in an upside down po- 
sition. 



2. Mesure: 

•Float height (T) 
Out of specification-* Adjust. 




Float height (F.H.): 

11.4-13.4 mm {0.45-0.53 in) 



NOTE: _ 

• Measure the distance from the mating surface 

of the float chamber (gasket removed) to the top 

of the float. 
•The float arm should be resting on the needle 

valve, but not compressing the needle valve. 




3. Adjust: 
• Float height 

***************************************** 
Adjustment steps: 

• Inspect the valve seat and needle valve. If either 
is worn, replace them both. 

• If both are fine, adjust the float height by bend- 
ing the float tang (T) on the float. 

• Recheck the float height. 

***************************************** 



5-9 





CARBURETOR 



CARB 


* 



FUEL LEVEL ADJUSTMENT 

1. Place the machine on a level place. 

2. Use a garage jack under the engine to ensure 
that the carburetor is positioned vertically. 

3. Attach the Fuel level gauge (J) to the float 
chamber nozzle. 



¥- 



Fuel level gauge: 
P/N YM-01312 



Loosen the drain screw @, and warm up the 
engine for several minutes. 
Measure: 
•Fuel level (3) 
Out of specification-* Adjust. 




Fuel level: 

3-4 mm {0.12-0.16 in) 
below the carburetor body edge. 



6. Adjust: 
• Fue level 

Adjustment steps: 

• Remove the carburetor. 

• Inspect the valve seat and needle valve. 

• If either is worn, replace them both. 

• If both are fine, adjust the float height by bend- 
ing the float tang © on the float. 

• Recheck the fuel level. 

***************************************** 



5-10 



WIRE CYLINDER 



UARd 


# 




WIRE CYLINDER 

REMOVAL 

1 . Remove: 

• Front fender 
•Fuel tank 

2. Unhook the rubber band and slide the band. 

3. Open: 

• Cover (wire cylinder) 

4. Disconnect: 

•Throttle cable (throttle lever side) (T) 

• Piston valve cable (carburetor side) (2) 
•Throttle valve cable (carburetor side) (3) 

CAUTION: 



Before removing the piston valve cable and 
throttle valve cable, make sure that the ad- 
justers and locknuts on the carburetor side 
are fully tightened. If not, the throttle does 
not operate properly. 



5. Remove: 
•Sliders 
•Spring 

NOTE: 

When removing the sliders, the spring will fall out. 
Take care not to lose this part. 




INSPECTION 

1. Inspect: 

• Cable ends (T) (throttle cable, piston valve 
cable and throttle valve cable) 
Damage-* Replace. 

•Sliders (2) 

Cranks/Wear-> Replace. 
•O-ring (3) 

• Rubber boots @ 
Damage-* Replace. 



5-11 



WIRE CYLINDER 



CARB 


« 




Check: 

•Slider operation 
Unsmooth operation 



Repair. 



INSTALLATION 

1. Apply: 

•Lithium base grease 
to the sliders and cable ends. 

2. Install: 
•Sliders (j) 
•Spring (2) 

NOTE: 



Before installing the sliders, do not forget to fit 
the spring. 

3. Connect: 

•Throttle cable {throttle lever side) (3) 
• Piston valve cable (carburetor side) (4) 
•Throttle valve cable {carburetor side) © 



NOTE: 



Before connecting the cables, insert the throttle 
cable (Throttle lever side) into the rubber band. 



CAUTION: 






^ 






f ~^- 
















1111 






SH9i 



Before installing the piston valve cable and 
throttle valve cable, make sure that the ad- 
justers and locknuts on the carburetor side 
are fully tightened. If not, the throttle does 
not operate properly. 

4. Install: 

•Cover (wire cylinder) 

5. Check: 

•Cable operation 
Unsmooth operation -► Repair. 

6. Hook the rubber band securely. 



5-12 



FRONT WHEEL AND WHEEL HUB 



CHASSIS 

FRONT WHEEL AND WHEEL HUB 



(T) Steering knuckle nut 
(D Washer 
(D Collar 

(4) Oil seal 

(5) Bearing 

© Wheel panel nut 

(7) Disc cover (Outer) 

(8) Wheel hub 



(§) Spacer 

(ft)) Brake disc 

(Q) Disc cover (Inner) 

© Steering knuckle 



CHAS 



O <> 



A 


TIRE SIZE: 


AT21 x 7-10 


B 


WEAR LIMIT: 


3.0 mm (0.12 in) 



C 


RIM SIZE: 


10x6 


D 


RIM RUNOUT LIMIT: 


RADIAL: 
2.0 mm (0.08 in) 


LATERAL: 
2.0 mm (0.08 in) 



28Nm(2.8m*kg,20ft»lb) 



28Nm(2.8m«kg,20ft*lb) 




45Nm{4,5m.kg,32ft.lb) 



6-1 



FRONT WHEEL AND WHEEL HUB 



CHAS 



ob 




REMOVAL 

1. Elevate the front wheels by placing a suita- 
ble stand under the front of the frame. 

2. Remove: 

•Wheel panel nut (T) 
•Front wheel 
•Disc cover (Outer) 



3. Remove: 

•Front brake caliper bolt (T) 



4. Remove: 
•Cotter pin (J) 
•Steering knuckle nut (2) 
•Washer 



5. Remove: 
•Caliper (T) 



6. Remove: 

•Front wheel hub and brake disc assembly 

© 
•Collar © 

CAUTION: 



Make sure the machine is properly sup- 
ported. 



6-2 



FRONT WHEEL AND WHEEL HUB 



CHAS 



4b* 



NOTE: 

Do not depress the brake lever when the brake 
caliper is off the disc otherwise the brake pads 
will be forced shut. 




7. Remove: 

•Disc cover (inner) (T) 



8. Remove: 

•Front brake disc © 
• Front wheel hub (2) 



INSPECTION 

1. Inspect: 
•Wheel 

Cracks/ Bends/ Warpage-* Replace. 

2. Measure: 
•Wheel runout 

Over specified limit -►Replace, wheel or 
check bearing play (3). 



& 


Rim runout limits: 


^\ 


Radial (T): 2.0 mm (0.08 in) 




Lateral (2): 2.0 mm (0.08 in) 



6-3 



FRONT WHEEL AND WHEEL HUB 



CHAS 



4& 




AWARDING 



'After mounting a tire, ride conservatively 
to allow proper tire to rim seating. Failure 
to do so may cause an accident resulting 
in machine damage and possible operator 
injury. 



3. Inspect: 

•Wheel bearings 

Wheel hub play/Wheel turns roughly-* 
Replace. 

***************************************** 

Wheel bearing replacement steps: 

• Clean wheel hub exterior. 

• Drive bearing out by pushing spacer aside and 
tapping around perimeter of bearing inner race. 
Use soft metal drift punch and hammer. The 
spacer (J) " floats" between bearings. Remove 
both bearings as described. 



AWARNING 



Eye protection is recommended when using 
striking tools. 



• To install the wheel bearing, reverse the above 
sequence. Use a socket that matches outside 
diameter of bearing outer race to drive in 
bearing. 

CAUTION: 



Do not strike the center race or balls of bear- 
ing. Contact should be made only with the 
outer race. 

***************************************** 



INSTALLATION 

When installing the front wheel, reverse the 
removal procedure. Note the following points. 
1. Apply: 

•Lithium base grease 
Lightly grease to the oil seal and bearing. 



6-4 



FRONT WHEEL 



CHAS 



o o 



Install: 

•Front brake disc 
•Disc cover (inner) 
• Front brake caliper 
•Axle nut 



X 


Front brake disc: 


28 Nm (2.8 nrkg, 20 ft»lb) 




Front brake caliper: 




28 Nm (2.8 nrkg, 20 ft. lb) 




Axle nut: 




85 Nm (8.5 m*kg, 61 ft*lb) 




3. Install: 

• Disc cover (outer) 

• Front wheels 

NOTE: 



•Install the disc cover (Outer) © with punched 
burns (2) on the hub side. 



4. Tighten: 

• Nuts (front wheel) 



P\ 



Nuts (front wheel): 
45 Nm (4.5 m-kg, 32 ft-lb) 




5. Install: 

•Cotter pin (new) (T) 
NOTE: 



Do not loosen the axle nut after torque tighten- 
ing. If the axle nut groove is not aligned with the 
cotter pin hole, align groove with the hole by 
tightening up on the axle nut. 



A WARNING 



Always use a new cotter pin. 



6-5 



REAR WHEEL AND WHEEL HUB 



CHAS 



c^d 



REAR WHEEL AND WHEEL HUB 



(T) Wheel panel nut 
©Axle nut 
(3) Washer 
@ Wheel boss 

§ Drive chain 
Driven sprocket 
(7) Nut 

® Sprocket boss 
(9) Dust cover 



® Oil seal 

® Bearing 

© Wheel hub 

@ Spacer 

® Brake disc boss 

<§ Brake disc 

(£§} Rear axle 




6-6 



REAR WHEEL AND WHEEL HUB 



CHAS 



4* 




REMOVAL 

1. Place the machine on a level place. 

2. Loosen: 

•Nuts (rear wheel) 
Apply the parking brake. 

3. Elevate the rear wheels by placing the suita- 
ble stand under the rear of frame. 



4. Remove: 

•Nuts (rear wheel) 
•Rear wheel 



Remove: 
•Cotter pin (T) 
•Axle nut (f) 
• Plain washer Q, 
•Wheel hub (4) 



Remove: 
•Nut © 




Rear axle nut wrench: 
YM-37132 



7. Remove: 

• Rear brake caliper assembly (J) 
NOTE: 



Do not depress the parking brake lever and brake 
pedal when the brake caliper is off the disc other- 
wise the brake pads will be forced shut. 



6-7 



REAR WHEEL AND WHEEL HUB 



CHAS 



£* 




■B . W-^^^ik^r 


i^^^^^^: -^H 




^^^H? 


• -siP^ ?1 




^Bl*^*^iHlJ 










^^^1 



8. Remove: 
• Rear axte (J) 

From the right side 
•Brake disc 



CAUTION: 



• Never directly tap the axle end with a ham- 
mer, this will result in damage to the axle 
thread and spline (2). 

• Install the wheel boss (§) and suitable sock- 
et (4) on the axle end to protect the thread 
and spline from damage. 



9. Remove: 

•Driven sprocket and sprocket boss assembly 
•Bolts (upper wheel hub) (T) 
•Bolts (lower wheel hub) (2) 
•Tensioner assembly (3) 
•Wheel hub (4) 



INSPECTION 

1. Inspect: 
•Wheel 

Refer to "FRONT WHEEL- INSPECTION" 
section 

2. Measure: 
•Wheel runout 

Refer to "FRONT WHEEL- INSPECTION" 
section. 




3. Inspect: 

• Rear axle runout @ 
Out of specification -"Replace. 




Rear axle runout limit: 
1.5 mm (0.06 in) 



^WARNING 



Do not attempt to straighten a bent axle. 



6-8 



REAR WHEEL AND WHEEL HUB 



CHAS 



4& 



4. Inspect: 

• Oil seals 
Damage-* Replace. 

5. Check: 

• Bearings 

Bearings allow play in the final gear hous- 
ing and rear hub or rear axle turns 
roughly-* Replace. Refer to "FRONT 
WHEEL" section. 

INSTALLATION 

When installing the rear wheel, reverse the 
removal procedure. Note the following points. 



Wheel hub installation 

1. Apply: 

• Lithium base grease 
Lightly grease to the oil seals and bearing. 

2. Install: 
•Wheel hub 
•Tensioner assembly 



\ 



Bolts (wheel hub — lower): 
50 Nm (5.0 m.kg, 36 ft- lb) 

Bolts (wheel hub — upper): 
100 Nm (10.0 m.kg, 72 ft* lb) 




Rear axle installation 

1. Install: 
•Brake disc 
• Rear axle © 
Tap the RIGHT END axle. 



CAUTION: 



• Ne\/er directly tap the axle end with a ham- 
mer, this will result in damage to the axle 
thread (j) and spline (2). 

• Install the wheel boss (D and suitable sock- 
et (4) on the axle end to protect the thread 
and spline from damage. 

2. Install: 

• Drive sprocket and sprocket boss assembly 



6-9 



REAR WHEEL AND WHEEL HUB 



CHAS 



o © 



3. Apply the brake pedal and parking brake. 

4. Install: 

•Nut (rear axle) 




5. Tighten: 

• Nuts (rear axle) ®, (2) 



*********#**##****##*#****#*-********##.x-** 



Nuts tightening steps: 
NOTE: 



Before tightening the nuts, apply the LOC- 
TITE® to the thread portion of the rear axle. 



• Finger tighten the inside nut (2) while check- 
ing the ring gear engagement. 

• Tighten the inside nut with Rear axle nut 
wrench to specification while holding the rear 
axle. 



n 



Rear axle nut wrench: 
YM-37132 




\ 



m 



Inside nut (first tightening): 
55 Nm (5.5 m*kg, 40 ft* lb) 



• Hold the inside nut (2) and tighten the outside 
nut ® with Rear axle nut wrench to specifi- 
cation. 



\ 



Outside nut: 

190 Nm (19.0 m-kg, 140 ft-lb) 



• Draw the line (a) on inside and outside nut. 

• Hold the outside nut ® and tighten BACK the 
inside nut (2) with Rear axle nut wrench to 
specification. 



\ 



Inside nut (final tightening): 
240 Nm (24.0 nvkg, 170 ft-lb) 



6-10 



• Measure the distance ® between lines. If dis- 
tance ® is less than 3 mm (0.12 in), retighten 
BACK the inside nut. 



REAR WHEEL AND WHEEL HUB 



CHAS 



o%£ 




6. Tighten: 
•Axle nuts 




Axle nuts: 

120 Nm (12.0 m.kg, 85 ft.lb) 



7. Install: 

•Cotter pins (new) (J) 



NOTE: 



Do not loosen the axle nut after torque tighten- 
ing. If the axle nut groove is not aligned with the 
cotter pin hole, align groove with the hole by 
tightening up on the axle nut. 



AWARNING 



Always use a new cotter pin. 



8. Install: 
•Rear wheels 

9. Tighten: 

•Nuts (rear wheel) 



K 



Nuts (rear wheel): 
45 Nm (4.5 m.kg, 32 ft.lb) 



10. Adjust: 

•Drive chain slack 
Refer to "CHAPTER 3. DRIVE CHAIN 
SLACK ADJUSTMENT" section. 



6-11 



FRONT BRAKE 

BRAKE CALIPER AND BRAKE DISC 

(D Brake disc 

(D Brake pads 

(3) Caliper piston assembly 

(4) Piston seal kit 
(D Shim 

(6) Air bleed screw 

(7) Retaining bolt 



FRONT BRAKE 



CHAS 



Ob 



NOTE: 

•Drain the brake fluid before removing the brake 

hose. 
•Always replace the brake pads as a set. 



A 


BRAKE PAD WEAR LIMIT: 
1.0 mm (0.004 in) 


B 


BRAKE DISC WEAR LIMIT: 
3.0 mm (0.12 in) 


C 


MAXIMUM DEFLECTION: 
0.5 mm (0.02 in) 



28 Nm (2.8 nvkg, 20 ft* lb) 



28 Nm (2.8 nvkg, 20 ft. lb) 





6-12 



FRONT BRAKE 



CHAS 



ob 



BRAKE HOSE AND MASTER CYLINDER 

(T) Copper washers 

(2) Master cylinder kit 

® Brake pipe 

® Clip 

(5) Brake hose 



NOTE: 



Always use a new brake pipe after removal. 



BRAKE FLUID: 
DOT No. 4 



B USE NEW ONE (1 



27 Nm {2.7 m.kg, 19 ft-lb) 



B USE NEW ONE 



10 Nm (1.0 m-kg, 7.2 ft. lb) 



18 Nm (1.8 m.kg, 13 ft*lb) 



B 




USE NEW ONE 



USE NEW ONE 



B USE NEW ONE 



6-13 



FRONT BRAKE 



CHAS 



^* 



CAUTION: 



Disc brake components rarely require disas- 
sembly. DO NOT: 

•Disassemble components unless absolutely 
necessary. 

•Use solvents on internal brake component. 

•Use contaminated brake fluid for cleaning. 

•Use only clean brake fluid. 

•Allow brake fluid to come in contact with 
the eyes otherwise eye injury may occur. 

• Allow brake fluid to contact painted sur- 
faces or plastic parts otherwise damage 
may occur. 

•Disconnect any hydraulic connection other- 
wise the entire system must be disassem- 
bled, drained, cleaned, and then properly 
filled and bled after reassembly. 



NOTE: 

Drain the brake fluid before removing brake hose. 




BRAKE PAD REPLACEMENT 

1. Remove: 
•Front wheel 
•Disc cover (outer) 
•Steering knuckle nut 
• Bolt (caliper) ® 



2. Remove: 

•Front wheel hub ® 
•Retaing bolt © 
• Brake pads (3) 



6-14 



FRONT BRAKE 



CHAS 



ob 





NOTE: 

Replace pads as a set if either is found to be worn 
to the wear limit. 




fl 



Brake pad wear limit: 
1.0 mm (0.04 in) 



3. Install: 

•Pads (new) © 
•Shim (2) 
•Retaining bolt (3) 



Be sure to install the shim (2) at piston side. 




\ 


Retaining bolt: 

18 Nm (1.8 m-kg, 13 ft-lb) 


4. Install: 
• Caliper 


X 


Bolt (caliper): 

28 Nm (2.8 m-kg, 20 ft-lb) 


•Steering knuckle 


5 


Axle nut: 

85 Nm (8.5 m-kg, 61 ft-lb) 



5. Install: 

•Disc cover (outer) © 
•Front wheel 



K 



Nut (wheel panel): 

45 Nm (4.5 m. kg, 32 ft-lb) 



NOTE: 

Install the disc cover (outer) © with punched 
burrs (2) on the hub side. 

CALIPER 
Caliper removal 

1. Remove: 
•Front wheel 
• Disc cover (outer) 
•Steering knucke 



6-15 



FRONT BRAKE 




■*•#.'■ 




CHAS 



oD 



• Brake hose (T) 

Drain the brake fluid. 
•Bolt (caliper) (2) 
•Disc cover (inner) 
•Brake pads 
•Pad spring 



Caliper disassembly 

1. Remove: 
•Dust seal © 
•Piston seal (2) 
•Piston ® 
Use compressed air and proceed carefully. 



ik WARNING 



• Cover piston with rag and use extreme cau- 
tion when expelling piston from cylinder. 

•Never attempt to pry out piston. 

*************************************##** 
Caliper piston removal steps: 

• Insert the rag into the caliper to lock the piston. 

• Blow compressed air into the hose joint open- 
ing to force out the piston from the caliper 

body. 

***************************************** 

Inspection 

1. Inspect: 
• Piston 

Rust/ Wear-> Replace. 
•Caliper cylinder body 

Wear/ Scratches -^ Replace. 



Installation 

1 . Assemble: 
• Brake caliper(s) 
Reverse disassembly steps. 



AWARNING 



•All internal parts should be cleaned in new 
brake fluid only. 



6-16 



FRONT BRAKE 



CHAS 



4& 




• Internal parts should be lubricated with 
brake fluid when installed. 



O 



Recommend brake fluid: 
DOT #4 

If DOT #4 is not available, #3 
can be used. 



• Replace the dust seat, piston seal and clip 
whenever a caliper is disassembled. 



2. Tighten: 

•Bolt (caliper) (J) 



K 



Bolt (caliper): 

28 Nm (2.8 m*kg, 20 ft* lb) 



Bolt (brake hose) 



K 



Bolt (brake hose): 
27 Nm (2.7 m»kg, 19 ft. lb) 



3. Bleed the air completely from the brake 
system. 



4. Install: 

•Steering knuckle 



X 



\ 



Axle nut: 

85 Nm (8.5 m-kg, 61 ft-lb) 



• Disc cover (outer) 
•Front wheel 



\ 



m 



Nut (wheel panel): 
45 Nm (4.5 rrrkg, 32 ft*lb) 



6-17 



FRONT BRAKE 




CHAS 



^* 



AIR BLEEDING 



AWARNING 



Bleed the brake system if: 

•The system has been disassembled. 

•A brake hose has been loosened or 
removed. 

•The brake fluid is very low. 

•The brake operation is faulty. 
A dangerous loss of braking performance 
may occur if the brake system is not proper- 
ly bled. 

Air bleeding steps: 

• Add proper brake fluid to the reservoir. 

• Install diaphragm. 

Be careful not to spill any fluid or allow the 
reservoir to overflow. 

• Connect the clear plastic tube (4.5 mm, 3/16 
in inside dia.) tightly to the caliper bleed screw 

®. 

• Place the other end of the tube into a container. 

• Slowly apply the brake lever several times. (*) 

• Pull the lever in. Hold the lever in position. 

• Loosen the bleed screw and allow the lever to 
travel towards its limit. 

• Tighten the bleed screw when the lever limit 
has been reached; then release the lever. (**) 

• Repeat steps (*) to {**) until all of the air bub- 
bles have been removed from the system. 



NOTE: 

If bleeding is difficult, it may be necessary to let 
the brake fluid system stabilize for few hours. 
Repeat the bleeding procedure when the tiny bub- 
bles in system have disappeared. 



6-18 



FRONT BRAKE 




CHAS 



©^o 



MASTER CYLINDER DISASSEMBLY 
Master cylinder removal 

NOTE: 

Drain the brake fluid before removing the master 
cylinder. 

1. Remove: 

•Brake hose ® 

•Brake lever (2) and spring 

•Master cylinder assembly (3) 

Master cylinder disassembly 

1. Remove: 
•Cap © 

Drain remaining fluid. 
•Master cylinder dust boot (2) 
•Circlip (3) 
•Master cylinder kit (4) 

NOTE: 

Be sure to reinstall the larger diameter lips of the 
cylinder cups first. 



Inspection 

1. Inspect: 

•Master cylinder body 
Scratches/Wear-* Replace. 

NOTE: 

Clean all passages with new brake fluid. 

•Brake hoses 

Cracks/Wear/ Damage-* Replace. 
•Master cylinder kit 

Scratches /Wear-* Replace. 




Installation 

1. Assemble: 
•Master cylinder 
Reverse disassembly steps. 



A WARNING 



Internal parts shoud be lubricated with brake 
fluid when installed. 



6-19 



FRONT BRAKE 



CHAS 



O |) 



2. Install: 

•Master cylinder 

• Brake hose (with copper washers) 

• Brake lever 

NOTE: 

Grease the pivot point. 




3. Tighten: 

•Master cylinder bolts 
• Brake hose 



\ 


Master cylinder: 


10 Nm (1.0 m.kg, 7.2 ft. lb) 




Brake hose: 




27 Nm (2.7 m.kg, 19 ft. lb) 



4. Bleed the air completely from the brake 
system. 

5. Tighten: 

• Master cylinder cap 



K 



Master cylinder cap: 

2 Nm (0.2 m.kg, 1.4 ft. lb) 




BRAKE DISC 

1. Remove: 
•Front wheel 
• Disc cover (outer) 



2. Inspect: 

•Brake disc (2) 
Wear/ Deflection 
Out of specification-* Replace. 




S 



Maximum deflection: 
0.15 mm (0.006 in) 

Minimum disc thickness: 
3.0 mm (0.12 in) 



6-20 



(T) Dial gauge 



FRONT BRAKE 



CHAS 



^ 



3, Install: 

•Disc cover (outer) 
•Front wheel 
Refer to "FRONT WHEEL-INSTALLA- 
TION" section. 



6-21 



REAR BRAKE 

© Bleed screw 
(D Brake pad 

S Caliper piston assembly 
Brake caliper 
(§) Brake disc 
©Shim 

(7) Copper washer 
(g) Union bolt 
(§) Master cylinder kit 



REAR BRAKE 



CHAS 



^ 



NOTE: 

•Be sure to position the shim so that its arrow 
mark ® points in the direction of the disc plate 
rotation ©. 



BRAKE DISC PAD 
WEAR LIMIT: 
1.0 mm (0.0394 in) 



BRAKE FLUID TYPE 

DOT #4 




ALL UNION BOLTS: 

27 Nm (2.7 m»kg, 19 ft»lb) 




12 Nm {1.2 m. kg, 13 ft. lb) 



|23Nm (2.3 m. kg, 17 ft .lb) 



BRAKE DISC 
WEAR LIMIT: 
3.5 mm (0.13 in) 



6-22 



REAR BRAKE 



CHAS 



cfa* 



Disc brake components rarely require disas- 
sembly. DO NOT: 

• Disassemble components unless absolutely 
necessary. 

• Use solvents on internal brake component. 

• Use contaminated brake fluid for cleaning. 
Use only clean brake fluid. 

•Allow brake fluid to come in contact with 
the eyes otherwise eye injury may occur. 

•Allow brke fluid to contact painted surfaces 
or plastic parts otherwise damage may 
occur. 

• Disconnect any hydraulic connection other- 
wise the entire system must be disassem- 
bled, drained, cleaned, and then properly 
filled and bled after reassembly. 



NOTE: _ 

Drain the brake fluid before removing brake hose. 




BRAKE PAD REPLACEMENT 

1. Remove: 
• Brake caliper (J) 



2. Remove: 

•Pad retaining bolts (T) 

• Lock washer (§) 
•Pad ® 

• Shim (J) 
•Pad spring 



6-23 



REAR BRAKE 



CHAS 



Ob 




3. Install: 

• Pad spring (new) 

• Pads (new) © 
•Shim @ 

NOTE: 



•Be sure to position the shim so that its arrow 
mark (3) points in the direction of the disc plate 
rotation. 

• Replace pads as a set if either is found to be 
worn to the wear limit. 




4. Install: 

•Lock washer (new) (J) 
• Pad retaining bolts (2) 



\ 



Pad retaining bolts: 

18 Nm (1.8 m.kg, 13 ft»lb) 



5. Install: 

•Brake caliper 



\ 



Brake caliper bolts: 
23 Nm (2.3 nvkg, 17 ft»lb) 




CALIPER DISASSEMBLY 

1. Disconnect: 

•Parking brake cable (J) 
•Brake hose © 

2. Remove: 
•Brake caliper (3) 



3. Remove: 

•Pad retaining bolts ® 

• Lock washer @ 
•Pad (3) 

• Shim (4) 
•Pad spring (5) 



6-24 




REAR BRAKE 



CHAS 



4* 



4. Remove: 

•Parking brake lever (T) 
• Spring © 




5. Remove: 
• Bolt © 
•Adjuster @ 
•Locknut (3) 

•Parking brake case assembly (4) 
•Gasket® 



(D (3) 




6. Remove: 
•Cover (j) 
•Spring (f) 
•Adjuster nut @ 
•Bearing @ 
• Parking brake case 




<&—% 



■® 



^ 



r 



£— <D 




7. Remove: 

•Caliper bracket bolt ® 
•Cover @ 
•Washer (J) 
•Cover (4) 
• Bracket (5) 




8, Remove: 

• Dust seal (T) 

•Piston seal (2) 

•Piston (3) 

•O-ring @ 
Use compressed air and proceed carefully. 



6-25 



REAR BRAKE 



CHAS 



cfc* 



AWARNING 



•Cover piston with rag and use extreme cau- 
tion when expelling piston from cylinder. 
•Never attempt to pry out piston. 




Caliper piston removal steps: 

• Insert the rag (T) into the caliper to lock the 
piston. 

• Blow compressed air (2) into the hose joint 
opening to force out the piston from the caliper 
body. 



MASTER CYLINDER DISASSEMBLY 

1. Remove: 
• Cotter pin 
•Washer 
•Pivot pin (j) 
•Bolts (2) 



2. Remove: 

•Brake hose ® 

• Union bolt (2) 

•Washer 

•Master cylinder assembly 



3. Remove: 

•Master cylinder kit 
(from master cylinder body) 



6-26 



REAR BRAKE 



CHAS 



O * 



INSPECTION AND REPAIR 

Refer to front brake inspection and repair except 
for following items. 



jjjBj 

■tf ( ) 



d) 




O 

® 



1. Inspect: 

•Caliper piston ® 
• Dust seal @ 
•Piston seal © 
•0- ring @ 
Damage/ Scratches -► Replace as a set. 




2. Inspect: 
•Brake pad 
Over wear limit (f) -» Replace as a set. 




Brake pad wear limit: 
1.0 mm (0.0394 in) 



Wear indicator 




3. Inspect: 

•Brake disc @ 
Wear/ Deflection 
Out of specification-* Replace. 




Maximum deflection: 
0.15 mm (0.006 in) 

Minimum disc thickness: 
3.5 mm (0.13 in) 



(T) Dial gauge 

ASSEMBLY 

Refer to front brake assembly except for follow- 
ing items. 



6-27 









REAR BRAKE 


CHAS 


4* 


.Ms 


4 flHHP ML ^ 


-® 


Caliper 

1. Tighten: 




5 


Caliper bracket bolt (T) 
23 Nm (2.3nvkg, 17 ft-lb) 














2. Mesh the bearing race tab (J) with parking 
brake case slit. 

3. Apply wheel bearing grease to the bearing ball 
(2) and races (3). 




4. Tighten 

•Parking brake case (T) 



\ 



Parking brake case bolt: 
28 Nm (2.8 m. kg, 20 ft- lb) 
Apply LOCTITE 



5. Align the adjuster nut mark (J) with the park- 
ing brake lever mark (2). 



6. Tighten: 



X 


Pad retaining bolt: 

18 IVIm (1.8 m-kg, 13 ft*lb) 
Brake caliper bolt: 

23 Nm (2.3 m-kg, 17 ft.lb) 
Brake union bolt: 






27 Nm (2.7 m-kg, 19 ft. lb) 





6-28 



REAR BRAKE 



CHAS 



^3* 




Master Cylinder 

1. Assemble: 
• Master cylinder 




Master cylinder bolt: 
20 Nm (2.0 m.kg, 14 ft»lb) 



2. Install: 

• Brake hose (j) 



K 



Union bolt (f): 
27 Nm {2.7 m-kg, 19 ft-lb) 



CAUTION: 



Be sure the brake hose should be installed 
between bosses (3). 




Brake Disc 

1. Install: 

• Brake disc (T) 



K 



Brake disc bolts (2): 
28 Nm (2.8 m.kg, 20 ft-lb) 



AIR BLEEDING 

Refer to "Front Brake Air Bleeding". 



6-29 



FRONT SUSPENSION 



CHAS 



6 



FRONT SUSPENSION 

(J) Thrust cover 

(D Bushing 

(D Front upper arm 

(§) Collar 

© Front lower arm 

(§) Shock absorber 

(7) Steering knuckle 




6-30 



FRONT SUSPENSION 



CHAS 



rf* 



REMOVAL 

1. Remove: 
•Front wheel 
• Front brake 
•Wheel hub 

Refer to FRONT WHEEL AND WHEEL 

HUB. 




2. Remove: 

•Front shock absorber 



3. Remove: 
•Cotter pins 

•Nut (left-hand-thread ball joint] (j) 
•Nut (front uper arm) (2) 
•Nut (front lower arm) (3) 



4. Remove: 

•Steering knuckle (T) 



NOTE: 



Use the General puller to separate ball joint (J) 
and steering knuckle. 



5. Remove: 

•Front upper arms (T) 
•Front lower arms (2) 



6-31 



FRONT SUSPENSION 




CHAS 



O * 



INSPECTION 

1. Inspect: 

•Front shock absorber 

Oil leaks/ Damage-* Replace. 
•Spring (T) 
•Bushing (2) 

Damage-* Replace. 




2. Inspect: 

• Steering knuckle 
Damage/ Pitting-* Replace. 




3. Inspect: 

•Front upper arm 
• Bushing (J) 

Pitting/ Damage-* Replace. 
•Thrust cover (2) 

Damage-* Replace. 
•Collar (3) 

Damage-* Replace. 



w». --,w 



® A -L^® 



m */ "-""•■# 




4. Inspect: 

• Front lower arm 
•Bushing © 

Pitting/ Damage-* Replace. 
♦Thrust cover (2) 

Damage-* Replace. 
•Collar (3) 

Damage-* Replace. 



6-32 



FRONT SUSPENSION 



CHAS 



©* 



INSTALLATION 

Reverse removal steps. 
1. Grease: 



^ 



Ball joint: 

Molybdenum grease 
Bushing, Thrust cover: 

Lithium soap base grease 




2. Tighten: 



\ 



Front arm 

(upper and lower) (j), (2): 
45 Nm (4.5 m*kg, 32 ft* lb) 



Install: 
•Steering knuckle 



X 


Nut 

(left-hand-thread ball joint) (J): 




25 Nm (2.5 m-kg, 18 ft-lb) 




Nut (front upper arm) (2): 




25 Nm (2.5 nrkg, 18 ft*lb) 




Nut (front lower arm) (3): 




25 Nm (2.5 m*kg, 18 ft*lb) 



4. Install: 

• Cotter pin (new) 




5. Install: 

•Front shock absorber 



\ 



Front shock absorber bolt: 
45 Nm (4.5 m-kg, 32 ft-lb) 



6-33 



STEERING SYSTEM 



CHAS 



4* 



STEERING SYSTEM 

(T) Lower bearing 

(2) Dust seal 

(D Upper bearing 

(§) Steering shaft 

(§) Right-hand-thread ball joint 

(|) Tie-rod 

(7) Steering knuckle 



(§) Left-hand-thread ball joint 

(D Oil seal 

© Bearing reatiner 

(fj) Bearing 

(J2> Collar 




6-34 



STEERING SYSTEM 



CHAS 



Ot) 




REMOVAL 

1. Remove: 

•Headlight unit assembly 

• Front panel 

•Upper handlebar holder (T) 

• Handlebar assembly (2) 



2. Remove: 

•Bolt © 
•Lock washer (2) 
•Bracket (3) 
•Upper bearing 



3. Remove: 
•Collars (J) 
•Dust seals (2) 
•Lower bearing (3) 



4. Remove: 
•Cotter pins © 

•Nut {right-hand-thread ball joint) 

5. Disconnect: 
•Tie-rod assembly (3) 



6. Remove 

•Cotter pin (T) 
•Nut (2) 
•Steering shaft 



6-35 



STEERING SYSTEM 



CHAS 



o* 






Rnc: 1 a^*-i 







Remove: 

• Front wheel 

(Refer to Front wheel and wheel hub) 

• Cotter pin © 

• Nut (left-hand-thread ball joint) (2) 



8. Loosen: 

• Left-hand-thread locknut © 
•Right-hand-thread locknut (2) 

9. Remove: 

• Left-hand-thread ball joint (3) 

• Right-hand-thread ball joint (4) 



10. Remove: 
•Oil seals © 
• Bearing retainer 



p. 



Damper rod holder: 
YM-01327 



• Bearing (3) 
•Collar (4) 

INSPECTION 

1. Inspect: 

• Steering shaft 
Bends-* Replace. 



AWARIMIIMG 



Do not attempt to straighten a bent shaft; 
this may dangerously weaken the shaft. 




Inspect: 
• Dust seals © 
•Steering shaft bushings ( 
Wear/ Damage-* Replace. 



6-36 



STEERING SYSTEM 



CHAS 



* 




3. Check: 

•Tie-rod ball joint free play and movement 
Exists free play-> Replace tie-rod ball joint. 
Turns roughly-* Replace tie-rod ball joint. 

4. Inspect: 
•Thrust cover 

Wear/Damage^ Replace. 



INSTALLATION 

When installing the tie-rod, reverse the removal 
procedure. Note the following points. 
1. Install: 

•Collar ® 

•Bearing (2) 

•Bearing retainer ® 



T 



Damper rod holder: 
YM-01327 



•Oil seals (4) 

2. Apply: 

• Lithium base grease 
Lightly grease to the steering shaft, 
bushings. 

3. Assembly: 
•Steering tie-rod 

***************************************** 
Tie-Rod assembly steps: 

• Install the left-hand-thread ball joint (T) and nut 
(2) into the flattened portions (3) side of the 
tie-rod. 

• Install the right-hand-thread ball joint (4) and 
nut (5) into the opposite side of the flattened 
portions (3). 

• Adjust the tie-rod length (7). 




Tie-rod length: 
325 mm (12.8 in) 



Turn the right-hand-thread ball joint (4) 20.5° 
Counterclockwise from the left-hand-thread ball 
joint (T) for the left tie-rod assembly and the ball 
joint (6) 20.5° clockwise for right tie-rod 
aseembly. 



6-37 



STEERING SYSTEM 



CHAS 



O^ 



NOTE 

The ba 




It joint thread length (8) must be the same. 


• Tighten: 


X 


Nuts (2), (f): 

30 Nm (3.0 m.kg, 22 ft- lb) 



• Mark: 
White paint (9) on the flattened portions side 
of the right tie-rod assembly. 



3. Tighten: 



X 


Tie-rod ball joint nuts: 


25 Nm (2.5 m.kg, 18 ft*lb) 




Steering shaft nut: 




30 Nm (3.0 m-kg, 22 ft*lb) 




Steering bearing bolts: 




23 Nm (2.3 m.kg, 17 ft-lb) 




4. Install: 

♦ Upper handlebar holder 



\ 



Upper handlebar holder bolts: 
20 Nm (2.0 m.kg, 14 ft-lb) 



NOTE: 

Be sure the upper handlebar holder mark (J) face 
to front. 

5. Adjust: 
•Toe-in 



6-38 



REAR SHOCK ABSORBER AND SWINGARM 
REAR SHOCK ABSORBER AND SWINGARM 



CHAS 


cfafr 



(T) Rear shock absorber 

(2) Reservoir tank 

(3) Swingarm 

© Drive chain guide 

(5) Pivot shaft 

(6) Thrust cover 1/2 
(j) Spacer 



(8) Oil seal 

(9) Bearing 
<0) Collar 1/2 

(Q) Drive chain protector 
@ Connecting rod 
(0) Relay arm 
(g) Rear guard 



<&> 




85 Nm (8.5 kg*m,61 ft-lb) 



(frt^^ 



48 Nm (4.8 kg«m,35 ft-lb) 



32 Nm (3.2 kg-m,23 fWb) 



6-39 



REAR SHOCK ABSORBER AND SWINGARM 



CHAS 


tt 



HANDLING THE REAR SHOCK ABSORBER 
AND GAS CYLINDER 



AWARNING 



This rear shock absorber and gas cylinder 
contain highly compressed nitrogen gas. 
Before handling the rear shock absorber or 
gas cylinder, read and make sure you under- 
stand the following information, the manu- 
facturer cannot be held responsible for prop- 
erty damage or personal injury that may 
result from improper handling of the rear 
shock absorber and gas cylinder. 
•Do not tamper or attempt to open the rear 
shock absorber or gas cylinder. 
•Do not subject the rear shock absorber or 
gas cylinder to an open flame or any other 
source of high heart. High heat can cause 
an explosion due to excessive gas pressure, 
•Do not deform or damage the rear shock 
absorber or gas cylinder in any way. If the 
rear shock absorber, gas cylinder or both 
are damaged, damping performance will 
suffer. 




DISPOSING OF A REAR SHOCK 
ABSORBER AND GAS CYLINDER 



Gas pressure must be released before dis- 
posing of shock absorber. To do so, drill (T) 
a 2-3 mm {0.08-0.12 in) hole through the 
gas chamber wall at a point 25-30 mm 
(1.0-1.2 in) from the bottom end of the gas 
chamber. 



AWARNIIMG 



Wear eye protection to prevent eye damage 
from released gas or metal chips. 



6-40 



REAR SHOCK ABSORBER AND SWINGARM 



CHAS 


£* 



REMOVING THE REAR SHOCK ABSORBER 

1. Remove 

•Reservoir tank 

• Connecting rod - to - swingarm bolt 

• Rear shock absorber upper bolt 
•Rear shock absorber 
•Connecting rod 

• Relay arm 

NOTE: 

While removing the connecting rod - to - 
swing arm bolt, hold the swingarm so that it 
does not drop down. 




CHECKING THE REAR SHOCK ABSORBER 

1. Check: 

•Shock absorber 

Oil leaks -+ Replace the rear shock 

absorber assembly. 
•Shock absorber rod 

Bends/damage -► Replace the rear shock 

absorber assembly. 
•Spring 

Fatigue -+ Replace the rear shock 

absorber assembly. 

Move the spring up and down. 
•Gas cylinder 

Damage/gas leaks -> Replace the rear 

shock absorber assembly. 




CHECKING THE RELAY ARM AND 
CONNECTING ARM 

1. Check: 
•Relay arm 
•Connecting arm 

Damage/wear -> Replace. 
•Bushings 
•Spacers 
•Oil seals 
6 . 41 Damage/pitting/scratches -► Replace. 



REAR SHOCK ABSORBER AND SWINGARM 



INSTALLING THE REAR SHOCK 
ABSORBER 

1. Install: 

• Connecting arm 

•Relay arm 

•Rear shock absorber 

NOTE: 



CHAS 


&$ 





When installing the rear shock absorber, lift 
up the swingarm. 

REMOVING THE SWINGARM 

NOTE: 

Before removing the drive chain and the 
sprockets, measure the drive chain slack and 
a ten link section of the drive chain. 

1. Check 

•Swingarm free play 

Checking steps: 

• Check the tightening torque of the pivot 
shaft nut. 



V 



Pivot shaft nut: 

85 Nm (8.5 nvkg, 61 ft-lb) 



• Check the swingarm side play [a] by moving 
it from side to side. 

If side play is noticeable, check the collar, 
spacers, bearings, bushings and frame 
pivot. 

• Check the swingarm vertical movement \b\ 
by moving it up and down. 

If vertical movement is tight or rough, or if 
there is binding, check the collar, spacers, 
bearings, bushings and frame pivot. 

2. Remove: 

• Pivot shaft nut 

• Pivot shaft 
•Swingarm 

CHECKING THE SWINGARM 

1. Check: 
•Swingarm 
Bends/cracks/damage -»■ Replace. 



6-42 



REAR SHOCK ABSORBER AND SWINGARM 



CHAS 


&6 




2. Check: 
•Pivot shaft 
Roll the axle on a flat surface. 
Bends ->■ Replace. 



AWARNING 



Do not attempt to straighten a bent pivot 
shaft. 



3. Clean: 

• Pivot shaft 
•Collar 
•Spacers 
•Bearings 

• Thrust cover 



,v> 



Recommended cleaning solvent: 
Kerosine 



©@©©@@@© ©@© 

xmSS5S5£5SS TFM I. 




4. Check: 

• Spacers 

• Oil seals 
Damage/wear -► Replace. 

•Bearings 
•Collar 
Damage/pitting -> Replace. 



CHECKING THE DRIVE CHAIN 

1. Measure: 

• Ten-link section © of the drive chain 
Out of specification -► Replace the drive 
chain. 




Max. ten-link drive chain section: 
152.5 mm (6 in) 



NOTE: 



•While measuring the ten - link section, push 
down on the drive chain to increase its ten- 
sion. 

•Measure the length between drive chain 
roller © and © as shown. 

•Perform this measurement at two or three 
different places. 



6-43 



REAR SHOCK ABSORBER AND SWINGARM 



CHAS 


tt 




2. Check: 
•Drive chain 
Stiffness - 
replace. 



Clean and lubricate or 



3. Clean: 
•Drive chain 

• Wipe the drive chain with a clean cloth. 

• Put the drive chain in kerosine and remove 
any remaining dirt. 

• Remove the drive chain from the kerosine 
and completely dry it. 



4. Lubricate: 
•Drive chain 



Recommended lubricant: 
Engine oil or 
chain lubricant suitable 



CD ® 


.. /T\ 






® 


^■+Jr^ ^^V 




/CS 






f\ x 


1 ( v 1 


/ 1 1 


1 \ V / i 


' " I 1 


i \ ^ / J 


\ \ 


J V. __^jriC^-^ 


^o / 


(2) 



5. Check: 

• Drive sprocket 

• Driven sprocket 

More than 1/4 tooth a wear -> Replace 
the drive chain sprockets as a set. 
Bent teeth -► Replace the drive chain 

sprockets as a set. 

(§) Correct 

(J) Drive chain roller 

(D Drive chain sprocket 

INSTALLING THE SWINGARM 

1. Install: 
•Collar 
(to swing arm) 

NOTE: 



Apply the lithium soap base grease on the 
bearing and bushing when installing. 



6-44 



YFM350XA CIRCUIT DIAGRAM 



ELECTRICAL 
YFM350XA CIRCUIT DIAGRAM 



ELEC 



*n 



B/W 



Br 



B/W 



Br 



— 



B/W 



B/W 



RUN 



OFF 



B/Y 



oo 



ENGAGED 



DISENGAGED 



B/Y- 



OiO 



REVERSE 



-,, „— _Q 

.^ F( 



•G/W * 



G/W Y/B 




■ W — 



W — 



W— 






OFF 



ON 



OO 



Br 



@ 



W/B 



<0 © 



© 



R -r 



oo 

TTT 

iRBr 

J L 



© 



R/W 




R/W 



T 
B 



•L/W- 



OFF 



ON 



•Br- 



Br 



OO 



© 



R/W" 



Y/B 



•W/B 



OFF 



LO 



HI 



Br 



ooo 



oo 




-K{fH*BM> 



'© 



G/L 



o 



ar. 

I 



REVERSE I FORWARD 






Br 






r 



7-1 



YFM350XA CIRCUIT DIAGRAM 




© CDI Magneto 

(D CDI unit 

® Ignition coil 

(|) Rectifier/ Regulator 

(5) Battery 

(D Fuse 

(2) Starter relay 

(§) Starter motor 

(f) Starting circuit cut-off relay 

(Q> Neutral relay 

(Q) Headlight (Left) 

© Headlight (Right) 

® Taillight 

(Q> "NEUTRAL" indicator light 

t "REVERSE" indicator light 
Main switch 
© "START" switch 
© "LIGHTS" (Dimmer) switch 
03) "ENGINE STOP" switch 
® Clutch switch 
(£D Neutral switch 
<§> Reverse switch 
(2) Lever switch 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

Orange 

R Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y Black/ Yellow. 

G/L Green/Blue 

G/W Green/White 

L/W Blue/White 

R/W Red/White 

W/B White/ Black 

W/G White/ Green 

Y/B Yellow/Black 



©<Q)®® @ © @>@> (H> @ 




®@@ 



7-2 



ELECTRICAL COMPONENTS 



ELECTRICAL COMPONENTS 

® Wireharness (9) Neutral switch 

(5) Neutral switch lead @ Reverse switch 

(D Starting circuit cut-off relay (Q) CDI unit 

@ Neutral relay @ Ignition coil 

(5) Starter relay <Q> Main switch 

(D Fuse @ "NEUTRAL" indicator light 

(2) Battery © "REVERSE" indicator light 

(§) Rectifier/ Regulator 



ELEC 


= 



SPECIFICATIONS 


RESISTANCE 


IGNITION COIL: 




PRIMARY 


0.72~0.98fl 


SECONDARY 


5.06~6.84kfi 


PICK-UP COIL 


180-220Q 


SOURCE COIL 


270-330A 


CHARGING COIL 


0.70-0.860 



A 


BATTERY: 


B 


CAPACITY: 
12V, 12AH 


C 


SPECIFIC GRAVITY: 
1.280 




7-3 



CHECKING OF SWITCHES 



ELEC 


+F 1- 



CHECKING OF SWITCHES 

Check the switches for the continuity between 
the terminals to determine correct connection. 

Read the following for switch inspection. 

SWITCH CONNECTION AS SHOWN IN 
MANUAL 

The manual contains a connection chart as shown 
left showing the terminal connections of the 
switches (e.g., main switch, handlebar switch, 
brake switch, lighting switch, etc.) 

The extreme left column indicates the switch po- 
sitions and the top line indicates the colors of 
leads connected with the terminals in the switch 
component. 













B 


B/W 




R 


Br 


L/W 


L/R 




ON 






o 


o 


o 


-o 


OFF 


o 


-O 










LOCK 


o 


-o 










P 


o 


\J 


a 






— /~} 






^J 









"O — O" indicates the terminals between which 
there is a continuity of electricity; i.e., a closed 
circuit at the respective switch positions. 

In this chart: 

"R and Br" and "L/W and L/R" are continuous 

with the "ON" switch position. 

"B and B/W" is continuous with the "OFF" 
switch position. 

"B and B/W" is continuous with the "LOCK" 
switch position. 



"B and B/W" and "R and L/R" are continuous 
with the "P" switch position. 

CHECKING SWITCH FOR TERMINAL 
CONNECTION 

Before checking the switch, refer to the connec- 
tion chart as shown above and check for the cor- 
rect terminal connection (closed circuit) by the 
color combination. 

To explain how to check the switch, the main 
switch is taken for example in the following. 



7-4 



CHECKING OF SWITCHES 



ELEC 




1 . Disconnect the main switch coupler from the 
wireharness. 

CAUTKSlsl? 



Never disconnect the main switch coupler 
by pulling the leads. Otherwise, leads may 
be pulled off the terminals inside the coupler. 

2. Inspect whether any lead is off the terminal 
inside the coupler. If it is, repair it. 



NOTE: __ 

If the coupler is clogged with mud or dust, blow 
it off by compressed air. 



3. Use the connection chart to check the color 
combination for continuity (a closed circuit). 
In this example, the continuity is as follows. 

"R and Br" and "L/W and L/R" are continu- 
ous with the "ON" switch position. 

"B and B/W" is continuous with the "OFF" 
switch position. 

"B and B/W" is continuous with the "LOCK" 
switch position. 

"B and B/W" and "R and L/R" are continu- 
ous with the "P" switch position. 

Please note that there is no continuity (an 
open circuit) at all for the color combinations 
other than the above. 

4. Check the switch component for the continui- 
ty between "R and Br". 

**#**#***##**#**************-****#*■***#*** 

Checking steps: 

• Turn the switch key to the "ON", "OFF", 
"LOCK", and "?" several times. 

• Set the pocket tester selector to the "Qx 1". 

• Connect the tester ( + ) lead to the "R" lead ter- 
minal in the coupler and the ( - ) lead to the 
"Br" lead terminal. 



7-5 



CHECKING OF SWITCHES 



ELEC 


+[ I- 






© 


(T) 






/T® 


OfC* 






lioL 




' N // 


dr 




UMiL 


y 



NOTE: 

Use thin probes for checking the continuity. 
Otherwise, the probes may contact other termi- 
nals inside the coupler. 

• Check the continuity between "R" and "Br" 
at the respective switch positions of "ON" (1), 
"OFF" ©, "LOCK" ®, and "P" (4). There 
must be continuity (the tester indicating "0") 
at the "ON" switch position, and there must 
be no continuity {the tester indicating "oo") at 
"OFF", "LOCK", or "P". There is something 
wrong between "R" and "Br" if there is no con- 
tinuity at the "ON" position or if there is some 
continuity either at the "OFF" or "LOCK" or 
"P". 

NOTE: 

Check the switch for continuity several times. 

***************************************** 

5. Next go on to checking of the continuity be- 
tween "B and B/W", "L/W and L/R", and 
"R and L/R" at the respective switch posi- 
tions, as in the same manner mentioned 
above. 

6. If there is something wrong with any one of 
the combinations, replace the switch com- 
ponent. 



7-6 



CHECKING OF BULBS 



ELEC 


H 1- 




CHECKING OF BULBS (FOR 
HEADLIGHT, TAIL/BRAKE 
LIGHT, FLASHER LIGHT, METER 
LIGHT, ETC.) 

Check the bulb terminal continuity for the condi- 
tion of the bulb. 

KINDS OF BULBS 

The bulbs used in the motorcycle are classified 
as shown left by the shape of the bulb socket. 

@ and ® are mainly used for the headlight. 

© is mainly used for the flasher light and tail/ 
brake light. 

© and (D are mainly used for the meter light and 
other indicator lights. 

CHECKING BULB CONDITION 

1. Remove the bulb. 

NOTE: 

• Bulbs of the @ and ® type uses a bulb holder. 
Remove the bulb holder before removing the 
bulb itself. Most of the bulb holders for this type 
can be removed by turning them counter- 
clockwise. 

•Most of the bulbs of © and ® type can be re- 
moved from the bulb sockets by pushing and 
turning them counterclockwise. 

•Bulbs of the (D type can be removed from the 
bulb sockets by simply pulling them out. 



Be sure to hold the socket firmly when 
removing the bulb. Never pull the lead. 
Otherwise, the lead may be pulled off the ter- 
minal in the coupler. 



A WARNING 



Keep flammable products or your hands 
away from the headlight bulb while it is on. 
It will be hot. Do not touch the bulb until it 
cools down. 



7-7 



CHECKING OF BULBS 



ELEC 


+1 "I- 



2. Check the bulb terminals for continuity. 




***************************************** 

Checking steps: 

• Set the pocket tester selector to the "Q, x 1". 

• Connect the tester leads to the respective bulb 
terminals. Take for example a 3-terminal bulb 
as shown left. First check the continuity be- 
tween the (J) and (2) terminals by connecting 
the tester ( + ) lead to the (J) terminal and the 
tester ( - ) lead to the (2) terminal. Then check 
the continuity between the (J) and (3) termi- 
nals by connecting the tester ( + ) lead still to 
the © terminal and the tester { - ) lead to the 
(3) terminal. If the tester shows "oo" in either 
case, replace the bulb. 

***************************************** 

3. Check the bulb socket by installing a proven 
bulb to it. As in the checking of bulbs, con- 
nect the pocket tester leads to the respective 
leads of the socket and check for continuity 
in the same manner as mentioned above. 



7-8 



IteCTRiC STARTING SYST1 



ELECTRIC STARTING SYSTI 
CIRCUIT DIAGRAM 




^^^^^^^^^^^^^^l^^^^^p^^p^ _ ^ 










. v ...,,,,,., s ,„.,„, „.„„.. ,.,.,,.,, ...jp^^^^^^^^S 

")..'' " ' '"'"" " '"" ' J " 







© 








ELECTRIC STARTING SYSTEM 




(5) 
© 
® 



© 



© 



CDI unit 

Battery 

Fuse 

Starter relay 

Starter motor 

Starting circuit cut-off relay 

Neutral relay 

"NEUTRAL" indicator light 

Main switch 

"START" switch 

"ENGINE STOP" switch 

Clutch switch 

Neutral switch 

Lever switch 



COLOR CODE 

B Black 

Br Brown 

G Green 

Gy Gray 

L Blue 

Orange 

R Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y Black/Yellow 

G/L Green/Blue 

G/Y Green/Yellow 

L/W Blue/White 

R/W Red/White 

W/B White/Black 

Y/B Yellow/Black 



® © @ (5)®®® 




7-10 



ELECTRIC STARTING SYSTEM 



ELEC 


+1 1- 




f— f R/W 

L/W ^ R/W 
\0 



O-Br- 



£ 



Idtfc 



-B-" 



© 



— W/B 
|-G/W-f- 



ByW G/Y 

D / ® / ^V 5 (0)7 

Y [ JReverse J 




STARTING CIRCUIT OPERATION 

The starting circuit on this model consist of the 
starter motor, starter relay, neutral switch, start- 
ing circuit cut-off relay, clutch switch, neutral re- 
lay and lever switch. If the main switch is on and 
the "ENGINE STOP" switch is RUN, the starter 
motor can be operated only if: 



•The transmission is in neutral (the neutral 
switch is on) and the select lever is in forward 
(the lever switch is closed), 
or 

• Pull in the clutch lever (the clutch switch is 
closed). 



NOTE: 

The starter motor can be operated irrespective of 
the engine stop switch ("OFF" or "RUN"); 
however, the engine can be started if the engine 
stop switch is at "RUN". 

The starting circuit cut-off relay prevents the start- 
er from operating when the transmission is in gear 
or select lever is in reverse, and clutch is engaged. 
In this instance, the starting circuit cut-off relay 
is off so that current cannot reach the starter 
motor. 



<D 



(Z> 

® 

® 

<S) 

[Aj 



Fuse 

Battery 

Starter relay 

Starter motor 

Starting circuit cut-off relay 

"START" switch 

CDI unit 

"ENGINE STOP" switch 

Clutch switch 

Lever switch 

Neutral switch 

Neutral relay 

"NEUTRAL" indicator light 

TO MAIN SWITCH 

FROM MAIN SWITCH 



7-11 



ELECTRICAL STARTING SYSTEM 



ELEC 



TROUBLESHOOTING 



STARTER MOTOR DOES NOT OPERATE. 



Procedure 

Check: 

1. Battery 

2. Fuse 

3. Main switch conduct 

4. "START" switch conduct 

5. "ENGINE STOP" switch conduct 

6. Clutch switch conduct 

7. Starter motor 



8. Starter relay 

9. Starting circuit cut-off relay 

10. Neutral relay 

11. Neutral switch conduct 

12. Lever switch conduct 

13. Wiring connection 



NOTE: 



•Remove the following parts before troubleshooting. 

1 ) Seat 

2) Front panel 

3) Front fender 

•Use the following special tools in this troubleshooting. 



§&*? Pocket Tester: 
]/ YU-03112 



CAUTION: 



To avoid damaging the CDI unit, do not test it by applying the battery voltage to it. 



1. Battery 



• Check the battery condition. Refer to "CHAP- 
TER 2. BATTERY INSPECTION" section. 



Specific Gravity: 
1.280 at 20°C (68°F) 



I 



CORRECT 



2. Fuse 



• Connect the Pocket Tester (Q x 1 ) to the fuse. 
•Check the fuse for continuity. 



J I CONTINUITY 



INCORRECT 




Refill battery fluid. Clean battery terminals. 
Recharge or replace battery. 



NOCONTINUITY 




Replace fuse. 



7-12 



ELECTRICAL STARTING SYSTEM 



ELEC 


l+i i-| 



£ 



3. Main switch conduct 



• Disconnect the main switch coupler {Red, 

Brown, Black/White and Black) from the 

wireharness. 
•Connect the Pocket Tester {Q x 1 ) to the main 

switch coupler (Black/White (T), Black (f), 

Red (D and Brown (4)). 



First Check A : 



Tester ( + ) Lead-* Black/White ® 

Lead 

Tester (-) Lead -► Black (2) Lead 



Second Check B 



Tester { + ) Lead -► Red (3) Lead 
Tester (-) Lead-Brown ® Lead 



B 





•Turn the main switch to ON and OFF. 
•Check the main switch for continuity. 



Switch 
Position 



Good 
Condition 



Bad 
Condition 



Switch 
Position 



Good 
Condition 



Bad 
Condition 



First Check (Black/White- Black) [a] 



Second Check I Red — Brown) \W\ 



ON 



O x O 



ON 



O 



o 



OFF 



O 



o 



OFF 



O 



o 



O: Continuity x : Nocontinuity 



•Connect the main switch coupler. 



INCORRECT 



2 



CORRECT 




4. "START" switch conduct 



•Disconnect the "START" switch couplers 
(Green, Brown, Yellow and Blue) and (Black, 
Black/ White and Red /White) from the wire- 
harness. 

•Connect the Pocket Tester (12x1) to the 
"START" switch coupler (Brown © and 
Red/White ©). 



Replace main switch. 



7-13 



ELECTRICAL STARTING SYSTEM 



ELEC 



H-l I- 



Tester ( + ) Lead-* Brown (T) Lead 
Tester (-) Lead -> Red/ White (2) Lead 








i \ 

fix 1 




fBr 


Q) 


? @ ? 


G 






Y 


L 











•Push the "START" switch and release it. 
•Check the "START" switch for continuity. 



Switch 
Position 



Push (ON) 



Release (OFF) 



Good 
Condition 



O 



Bad 
Condition 



O x O 



O 



O: Continuity x: Nocontinuity 



• Connect the "START" switch coupler. 



J I CORRECT 



5. "ENGINE STOP" switch conduct 



• Disconnect the "ENGINE STOP" switch cou- 
pler (Black, Black/ White and Red/ White) 
from the wireharness. 

•Connect the Pocket Tester (0 x 1 ) to the "EN- 
GINE STOP" switch coupler (Black/White 
® and Black (2)). 



Tester ( + ) Lead-* Black/ White (j) Lead 
Tester (-) Lead->Black (2) Lead 




£2x1 






INCORRECT 




Replace "START" switch. 



7-14 



ELECTRICAL STARTING SYSTEM 



ELEC 


T\ (- 



•Turn the "ENGINE STOP" switch to RUN and 
OFF. 

•Check the "ENGINE STOP" switch for con- 
tinuity. 



Switch 
Position 



RUN 



OFF 



Good 
Condition 



O 



Bad 
Condition 



O x O 



x O 



O: Continuity x: Nocontinuity 



• Connect the "ENGINE STOP" switch coupler. 



J 



CORRECT 



6. Clutch switch conduct 



• Disconnect the clutch switch leads {Black/ 
Yellow and Black) from the wireharness. 

•Connect the Pocket Tester (Qx1) to the 
clutch switch leads (Black/ Yellow (T) and 
Black ©). 



Tester ( + ) Lead ^Black/Yellow (T) Lead 
Tester (-) Lead -+ Black (2) Lead 



DISENGAGED 



ENGAGED 



<sf 






S7x 1 



©. 



-C3<*- 



tJ 



•Grab the clutch lever and release the clutch 
lever. 
•Check the clutch switch for continuity. 



Lever 
Position 



Grab Lever 



Release Lever 



Good 
Condition 



O 



Bad 
Condition 



O 



o o 



O: Continuity x : Nocontinuity 



•Connect the clutch switch leads. 



J I CORRECT 



INCORRECT 



1 



Replace "ENGINE STOP" switch. 



INCORRECT 




7-15 



ELECTRICAL STARTING SYSTEM 



ELEC 


±L-U 



4 



7. Starter motor 



•Connect the battery (12V) to the starter mo- 
tor cable (T) using the jumper lead (2)-*. 



Battery { + ) Terminal (3) 
Starter Motor Cable 






| — ■ — — -u u 

? LizF 




© e 



•Check the starter motor operation. 



J 



MOVES 



8. Starter relay 



• Disconnect the starter relay coupler (Blue/ 

White and Black). 
•Connect the starter relay coupler (Blue/ White 

(4) and Black (§)) to the battery (12V). 



Battery ( + ) Lead (f)-> Blue/ White (4) 

Lead 

Battery (-) Lead (5)->Black (§) Lead 



■^ 



AWARNING 



•A wire for the jumper lead must have the 
equivalent capacity as that of the battery 
lead or more, otherwise it may cause the 
jumper lead to be burned. 

•This check is likely to produce sparks, so 
be sure that no flammable gas or fluid is in 
the vicinity. 



DOES NOT MOVE 




Repair or replace starter motor. 




•Check the starter motor operation. 
• Connect the starter relay coupler. 



J I MOVES 



■* 



7-16 



ELECTRICAL STARTING SYSTEM 



ELEC 



& 



9. Starting circuit cut-off relay 



►Disconnect the starting circuit cut-off relay 
© coupler {Red /White, Red/White, Blue/ 
White and Yellow/ Black) from the wire- 
harness. 




•Connect the starting circuit cut-off relay cou- 
pler {Yellow/ Black (§), Red/ White ®, Red/ 
White (D and Blue/White (§)) to the Pocket 
Tester (0x1) and battery {12V) (2). 



Tester ( + ) Lead -* Red/ White (5) Lead 

Tester (-) Lead-* Blue/White (6) Lead 

Battery ( + ) Lead-^ Yellow/Black (§) 

Lead 

Battery {-) Lead -» Red/ White (4) Lead 




►Check the starting circuit cut-off relay for con- 
tinuity. 



E3 



Battery 
Connected 



Battery 
Disconnected 



Good 
Condition 



O 



Bad 
Condition 



O 



O 



o 



O: Continuity x : Discontinuity 



•Connect the starting circuit cut-off relay 
coupler. 



¥ 



CORRECT 



* 



INCORRECT 




Replace starting circuit cut-off relay. 



7-17 



ELECTRICAL STARTING SYSTEM 



ELEC 



ffl l-l 



■a 



10. Neutral relay 



►Disconnect the neutral relay (J) coupler 
(Green/ Yellow, Brown, White/ Black and Sky 
blue) from the wireharness. 




•Connect the neutral relay coupler (Green/ 
Yellow (3), Brown (4), White/ Black (5) and 
Sky blue (6)) to the Pocket Tester (Q x 1 ) and 
battery (12V) @. 



Tester ( + ) Lead -> White/ Black (5) Lead 
Tester (-) Lead->Sky blue (6) Lead 
Battery ( + ) Lead->Brown (4) Lead 
Battery (-) Lead->Green/Yellow (3) 
Lead 




»Check the neutral relay for continuity. 



E3 



Battery 
Connected 



Battery 
Disconnected 



Good 
Condition 



O 



Bad 
Condition 



O 



O 



o 



O: Continuity x: Discontinuity 



•Connect the neutral relay coupler. 



u 



CORRECT 



* 



INCORRECT 



* 



Replace neutral relay. 



7-18 



ELECTRICAL STARTING SYSTEM 



ELEC 


TT 1- 



■* 



£ 



11. Neutral switch conduct 



• Disconnect the neutral switch lead (Sky blue) 
from the wireharness. 

•Connect the Pocket Tester {Q x 1 ) to the neu- 
tral switch lead (Sky blue (J)) and engine. 



Tester ( + ) Lead -> Sky blue (J) Lead 
Tester (-) Lead -^Engine (Ground (g 



•>r 



i 



fix 1 



©; 



•Shift the neutral and reverse. 

•Check the neutral switch for continuity. 



Transmission 
Position 



In neutral 



In gear 



Good 
Condition 



O 



Bad 
Condition 



O x 



O 



o 



O: Continuity x : Nocontinuity 



• Connect the neutral switch lead. 



I 



CORRECT 



12. Lever switch conduct 



•Disconnect the lever switch lead (Green/ 

White) from the wireharness. 
•Connect the Pocket Tester (12 x 1 ) to the lever 

switch lead (Green/White (T)) and engine. 



Tester ( + ) Lead-* Green /White (J) Lead 
Tester (-) Lead-*Engine (Ground (2)) 



INCORRECT 




Replace reverse switch. 



7-19 



ELECTRICAL STARTING SYSTEM 



ELEC 


+1 1- 




Hx 1 



J 



o- n 



'Shift the neutral and gear. 

'Check the lever switch for continuity. 



Transmission 
Position 



Forward 



Reverse 



Good 
Condition 



O 



Bad 
Condition 



O 



O x 



O 



O: Continuity x: Nocontinuity 



•Connect the reverse switch lead. 



I 



CORRECT 



13. Wiring connection 

(Entire electrical starting system) 



•Check the entire electrical starting system for 
connections. Refer to "WIRING DIAGRAM" 
section. 



I 



CORRECT 



CDI unit is faulty. Replace it. 



INCORRECT 




POOR CONNECTION 






Correct. 



7-20 



CHARGING SYSTEM 



ELEC 



ST 



CHARGING SYSTEM 



CIRCUIT DIAGRAM 




7-21 



CHARGING SYSTEM 



ELEC 


TT 1- 



(T) CDI Magneto 

@ Rectifier/ Regulator 

(5) Battery 

(6) Fuse 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

Orange 

R Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y Black/Yellow 

G/L Green/Blue 

G/W Green/White 

L/W Blue/White 

R/W Red/White 

W/B White/Black 

W/G White/Green 

Y/B Yellow/Black 



© ©C4) 




7-22 



CHARGING SYSTEM 



ELEC 



E~ 



TROUBLESHOOTING 



THE BATTERY IS NOT CHARGED. 



Procedure 

Check; 

1. Fuse 

2. Battery 

3. Charging voltage 



4. Charging coil resistance 

5. Wiring connection 
(Entire charging system) 



NOTE: 



• Remove the following parts before troubleshooting. 
1 ) Seat 
•Use the following special tool(s) in this troubleshooting. 



m 



Inductive tachometer: 
P/N. YU-08036 



it 



Pocket tester: 
P/N. YU-03112 



1. Fuse 



•Check the fuse condition. Refer to the "FUSE 
INSPECTION" section in the CHAPTER 3. 



\ 



CORRECT 



2. Battery 



• Check the battery condition. Refer to the 
"BATTERY INSPECTION" section in the 
CHAPTER 3. 



Specific gravity: 
1.280 at 20°C (68°F) 



I 



CORRECT 



3. Charging voltage 



• Connect the Inductive tachometer to the 
spark plug lead. 



INCORRECT 



Fuse is faulty, replace it. 



INCORRECT 




• Refill battery fluid. 

• Clean battery terminals. 
•Recharge or replace battery. 



7-23 



CHARGING SYSTEM 



ELEC 


+1 1- 



• Connect the Pocket tester (DC20V) to the 
battery. 



Tester ( + ) lead -> Battery positive ter- 
minal 

Tester (-) lead^ Battery negative ter- 
minal 




•Turn the "LIGHT" (Dimmer) switch to "OFF" 

position. 

•Start the engine. 
•Accelerate the engine to specifications and 

check the charging voltage. 



B3 



, Q~o J 



Charging voltage: 

14- 15V at 5,000 r/min 



T 



OUT OF 
SPECIFICATION 



4. Charging coil resistance 



• Disconnect the CDI magneto leads from the 
wireharness. 

• Connect the Pocket tester (12x1) to the 
charging coil leads. 



Charging coil (1): 
Tester ( + ) lead -+ White lead (J) 
Tester (-) lead -> White lead (2) 



Charging coil (2): 

Tester ( + ) lead ~> White lead (J) 
Tester (-) lead -* White lead (3) 




MEETS SPECIFICATION 



1 



Charging system is good. 



7-24 



CHARGING SYSTEM 



ELEC 


+1 1- 



• Check the charging coils for specificated 
resistance. 



OUT OF SPECIFICATION 



E3 



Charging coil resistance: 
0.70-0.86Q at20°C (68°F) 
(White-White) 



I 



Charging coils are faulty, replace them. 



BOTH RESISTANCES 
MEET SPECIFICATIONS 



5. Wiring connection 



POOR CONNECTION 



• Check the entire charging system for connec- 
tions. Refer to the "WIRING DIAGRAM" 
section. 



I 



CORRECT 



Rectif ire/ Regulator is faulty, replace it. 



1 



Correct. 



7-25 



CHARGING SYSTEM 



ELEC 


71 "" 1- 



7-26 



IGNITION SYSTEM 



ELEC 





IGNITION SYSTEM 

CIRCUIT DIAGRAM 




7-27 



SCDI magneto 
CDI unit 
(D Ignition coil 
(D Battery 
® Main switch 
(f$ "ENGINE STOP" switch 



IGNITION SYSTEM 



ELEC 


[+1 l-| 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

Orange 

R Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y Black/Yellow 

G/L Green/Blue 

G/W Green/White 

L/W Blue/ White 

R/W Red /White 

W/B White/Black 

W/G White/Green 

Y/B Yellow/Black 




7-28 



IGNITION SYSTEM 



ELEC 



TROUBLESHOOTING 



IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE 
(NO SPARK OR INTERMITTENT SPARK) 



Procedure 

Check; 

1. Spark plug 

2. Ignition spark gap 

3. Spark plug cap resistance 

4. Ignition coil resistance 

5. Main switch 



6. "ENGINE STOP" switch 

7. Source coil resistance 

8. Pickup coil resistance 

9. Wiring connection (Ignition system) 



NOTE: 

• Remove the following parts before troubleshooting. 

1 ) Headlight unit assembly 4) Fuel tank cover 

2) Seat 5) Front fender 

3) Front panel 6) Fuel tank 
•Use the following special tools in this troubleshooting. 



m 



Pocket Tester: 
YU-03112 



n 



Dynamic Coil Tester: 
YM-34487 



1. Spark plug 



• Check the spark plug type condition and gap. 
Refer to the "SPARK PLUG INSPECTION" 
section in the CHAPTER 3. 



Standard Spark Plug: 

D8EA (NGK) or X24ES-U (ND) 



INCORRECT 




Spark Plug Gap: 

0.6-0.7 mm (0.024-0.028 in) 




377-000 



I 



I 



Repair or replace spark plug. 



CORRECT 



* 



7-29 



IGNITION SYSTEM 



ELEC 



EC 



■* 



A 



2. Ignition spark gap 



► Disconnect the spark plug cap from the spark 
plug. 

►Connect the Dynamic Spark Tester ® be- 
tween the spark plug (2) and spark plug cap 
(§), and set the specified spark gap. 




^J 



•Turn the main switch to "ON" and "ENGINE 
STOP" switch to "RUN", then, shift the gear 
in neutral. 

•Start the engine. 

• Check the ignition spark condition. 




^ Minimum Spark Gap: 
6 mm (0.24 in) 



SPARK 



^y 



Ignition circuit is good. 



OUT OF SPECIFICATION 



3. Spark plug cap resistance 



• Remove the spark plug cap. 
•Connect the Pocket Tester (Ox 1k) to the 
spark plug cap. 




•Check the spark plug cap for specificated 
resistance. 



OUT OF SPECIFICATION 



E3 






Spark Plug Cap Resistance: 
10kO at 20°C (68°F) 



~# 




MEETS 
SPECIFICATION 



* 



7-30 



IGNITION SYSTEM 



* 



-a 



4. Ignition coil resistance 



•Disconnect the ignition coil lead (Orange) 
from the wireharness. 
• Connect the Pocket Tester to the ignition coil. 



Primary Coil: {12x1) 
Tester ( + ) Lead-»Orange (j) Terminal 
Tester (-) Lead -> Ignition Coil Base 

Secondary Coil: (Ox Ik) 

Tester ( + ) Lead -*■ Spark Plug lead (2) 
Tester (-) Lead-* Ignition Coil Base 



(D— J* 3 ** 



H 







W 



® 



+ 



u 



•Measure the primary and secondary coil 
resistances. 



E3 



Primary Coil Resistance \j\\ : 
0.36-0.480 at 20°C (68°F) 

Secondary Coil Resistance [JB 
5.44~7.36k0 at 20°C (68°F) 



I 



MEETS BOTH 
SPECIFICATIONS 



ELEC 


M 



OUT OF SPECIFICATION 




7-31 



IGNITION SYSTEM 



ELEC 



Dr 



5. Main switch 



• Disconnect the main switch coupler (J) from 
the wireharness. 

•Check the switch component for the continui- 
ty between "Black/White (2) and Black (3)". 
Refer to the "CHECKING OF SWITCHES" 
section. 






12x1 






?®f 




^B/W Br * 
\\ B R J 





CORRECT 



6. "ENGINE STOP" switch 



•Disconnect the "ENGINE STOP" switch cou- 
pler (j) from the wireharness. 

•Check the switch component for the continui- 
ty between "Black/ White @ and Black (3)". 
Refer to the "CHECKING OF SWITCHES" 
section. 




INCORRECT 




Replace main switch. 



INCORRECT 



Replace handlebar switch. 



7-32 



IGNITION SYSTEM 



ELEC 



£ 



7. Source coil resistance 



• Disconnect the CDI magneto coupler (T) 

from the wireharness. 
•Connect the Pocket Tester (fix 100) to the 

source coil. 



Tester ( + ) Lead -> White/Green (2) 

Terminal 

Tester (-) Lead -► Red (3) Terminal 





w/g] — @ 



dr* 



• Measure the source coil resistance. 



E3 



Source Coil Resistance: 
270~330fi at20°C (68°F) 



I I MEETS 
JL SPECIFICATION 



8. Pickup coil resistance 



•Disconnect the CDI magneto coupler (T) 
from the wireharness. 

►Connect the Pocket Tester (fix 100) to the 
pickup coil. 



Tester ( + ) Lead ^ Blue (2) Terminal 
Tester (-) Lead-* Yellow (3) Terminal 





^RD 



OUT OF SPECIFICATION 




7-33 



IGNITION SYSTEM 



ELEC 



'Measure the pickup coil resistance. 



E3 



Pickup Coil Resistance: 
171-2090 at 20°C (68°F) 



J 



MEETS 
SPECIFICATION 



9, Wiring connection 



• Check the entire ignition system for con- 
nections. 

• Refer to the "WIRING DIAGRAM" section. 



J I CORRECT 



CDI unit is faulty. Replace it. 



OUT OF SPECIFICATION 




POOR CONNECTION 




Correct. 



7-34 



LIGHTING SYSTEM 




(T) CDI Magneto 

(4) Rectifier/ Regulator 

CD Battery 

© Fuse 

(Q) Headlight (Left} 

© Headlight (Right) 

@ Taillight 

@) Main switch 

® "LIGHTS" (Dimmer) switch 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

Orange 

R . . Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y Black/Yellow 

G/L Green/Blue 

G/W Green/White 

L/W Blue/ White 

R/W Red/ White 

W/B White/Black 

W/G White/Green 

Y/B Yellow/Black 



© <n>® 



®® ®@ 




7-36 



LIGHTING SYSTEM 



ELEC 


tt 11 " r- 



LIGHTING SYSTEM 

CIRCUIT DIAGRAM 




7-35 



LIGHTING SYSTEM 



ELEC 



n — f 



TROUBLESHOOTING 



HEADLIGHT TAIL LIGHT DO NOT COME ON 



Procedure 

Check; 

1. Bulb and bulb socket 

2. Battery 

3. Fuse 



4. "LIGHTS" (Dimmer) switch 

5. Main switch 

6. Wiring connection (Lighting system) 



NOTE: 



•Remove the following parts before troubleshooting. 
1) Front panel 2) Seat 

•Use the following special tool in this troubleshooting. 



m 



Pocket Tester: 
YU-03112 



1. Bulb and bulb socket 



•Remove the bulb. 
Refer to "CHAPTER 3. HEADLIGHT BULB 
REPLACEMENT". 

• Check the bulb and bulb socket for continui- 
ty. Refer to the "CHECKING OF BULBS" 
section. 



J 



CONTINUITY 



2. Battery 



►Check the battery condition. 
»Check the battery fluid level, battery termi- 
nals and specific gravity. 
Refer to the "BATTERY INSPECTION" sec- 
tion in the CHAPTER 3. 



Specific Gravity: 
1.280 at 20°C (68°F) 



u: 



CORRECT 



NOCONTINUITY 



1 



Replace bulb. 



INCORRECT 




• Refill battery fluid. 
•Clean battery terminals. 
•Recharge or replace battery. 



"7T 



7-37 



LIGHTING SYSTEM 



Jk 



3. Fuse 



NOCONTINUITY 



•Connect the Pocket Tester "0x1" to the 
fuse. 
•Check the fuse for continuity. 



CONTINUITY 



Replace fuse. 



4. "LIGHTS" (Dimmer) switch 



• Check the switch component for the continui- 
ty between "Brown (J) and Blue (2)", 
"Brown (T) and Green (§)" and "Brown (J) 
and Yellow (4)". 

Refer to the "CHECKING OF SWITCHES" 
section. 



[A] Headlight 
OS Taillight 



INCORRECT 



ELEC 





^y 



CORRECT 



I 



5. Main switch 



•Disconnect the main switch coupler (T) from 
the wireharness. 

•Check the switch component for the continui- 
ty between "Red ® and Red (3)". 
Refer to the "CHECKING OF SWITCHES" 
section. 



Replace handlebar switch. 



7-38 



LIGHTING SYSTEM 



ELEC 






6. Wiring connection 



> Check entire lighting system for connections. 
Refer to "WIRING DIAGRAM" section. 



I 



OK 



Check the charging system. 



INCORRECT 



1 



Replace main switch. 



POOR CONNECTION 




Correct. 



7-39 



LIGHTING SYSTEM 



IhIhIwV/ 



7-40 



SIGNAL SYSTEM 



ELEC 


+i i- 



SIGNAL SYSTEM 

CIRCUIT DIAGRAM 




7-41 



(5) Battery 

(D Fuse 

© Neutral relay 

® "NEUTRAL" indicator light 

© "REVERSE" indicator light 

© Main switch 

(St) Neutral switch 

(2z> Reverse switch 



SIGNAL SYSTEM 



ELEC 


^ 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

Orange 

R Red 

Sb Skyblue 

W White 

Y Yellow 

B/W Black/White 

B/Y ., Black/Yellow 

G/L Green/Blue 

G/W Green/White 

L/W Blue/White 

R/W Red/White 

W/B White/Black 

W/G White/Green 

Y/B Yellow/Black 



®® <E> 




7-42 



SIGNAL SYSTEM 



ELEC 



TROUBLESHOOTING 



"NEUTRAL" INDICATOR LIGHT AND "REVERSE INDICATOR LIGHT" DO NOT COME ON. 



Procedure 

Check; 

1. Fuse 

2. Battery 

3. Main switch 

4. Wiring connection 
(Entire signal system) 

NOTE: 



•Remove the following parts before troubleshooting. 
•Front cover • Fuel tank 

• Handlebar cover 

• Seat 

•Use the following special tool(s) in this troubleshooting. 



m 



Pocket Tester: 
P/N. YU-03112 



1. Fuse 



►Remove the fuse. 

►Connect the Pocket Tester (ft x 1 ) to the fuse. 

►Check the fuse for continuity. 



1 



CONTINUITY 



2. Battery 



Check the battery condition. Refer to the 
"BATTERY INSPECTION" section in the 
CHAPTER 3. 



Specific Gravity: 
1.280 at 20°C (68°F) 



J 



CORRECT 



NO CONTINUITY 




Replace fuse. 



INCORRECT 



\ 



• Refill battery fluid. 
•Clean battery terminals. 
•Recharge or replace battery. 



7-43 



SIGNAL SYSTEM 



ELEC 


TT 1- 



-0- 



3. Main switch 



•Disconnect the main switch lead (T) from the 
wireharness. 

•Check the switch component for the continui- 
ty between "Red (2) and Brown (J)". 
Refer to the "CHECKING OF SWITCHES" 
section. 





I 




CORRECT 



4. Wiring connection 



Check the entire signal system for connections. 
Refer to the "WIRING DIAGRAM" section. 



J 



CORRECT 



Check condition of each circuit for signal sys- 
tem. Refer to "SIGNAL SYSTEM CHECK" 
section. 



POOR CONNECTION 




Correct. 



7-44 



SIGNAL SYSTEM 



ELEC 


H 1- 



SIGNAL SYSTEM CHECK 

1. "NEUTRAL" indicator light does not come on. 



1. Bulb and bulb socket 



Check the bulb and bulb socket for continuity. 



3E 



CONTINUITY 




2. Neutral switch 



• Disconnect the neutral switch coupler ® 
from the wireharness. 

• Check the switch component for the continui- 
ty between "Sky blue" lead (2) and frame 
earth (3). 




3. Voltage 



• Connect the Pocket Tester (DC20V) to the 
bulb socket connector. 



Tester { + ) Lead ->" Brown" (J) lead 
Tester {-) Lead-^Frame earth (2) 




•Turn the main to "ON". 
• Shift in neutral. 

•Check for voltage (12V) on the "Brown" lead 
and frame earth. 



¥ 



Bulb and/or bulb socket are faulty, replace. 



INCORRECT 



Neutral switch is faulty, replace it. 



OUT OF SPECIFICATION 




Wiring circuit from main switch to bulb sock- 
et connector is faulty, repair. 



MEETS 
SPECIFICATION (12V) 



This circuit is good. 



7-45 



SIGNAL SYSTEM 



SIGNAL SYSTEM CHECK 

1. "REVERSE SIGNAL SYSTEM" indicator light does not come on. 



ELEC 



H-l I- 



1. Bulb and bulb socket 



Check the bulb and bulb socket for continuity. 



I 



CONTINUITY 



2. Reverse switch 



►Disconnect the reverse switch coupler © 
from the wireharness. 

►Check the switch component for the continui- 
ty between "Green /Blue" (2) and frame 
earth. 




IN REVERSE 



FORWARD 



o— o 



:i; 0, 




¥ 



CORRECT 



3. Voltage 



►Connect the Pocket Tester (DC20V) to the 
bulb socket connector. 



Tester ( + ) Lead-* "Brown" (J) lead 
Tester (-) Lead-* Frame earth (2) 



Qc 



□ 



!r-WZ3 



g/lHZX} 



•Turn the main switch to "ON". 
• Shift in "FORWARD". 
•Check for voltage (12V) on the "Brown" lead 
and frame earth. 



I 



MEETS 
SPECIFICATION {12V) 



This circuit is good. 



NO CONTINUITY 




Bulb and/or bulb socket are faulty, replace. 



INCORRECT 




Reverse switch is faulty, replace it. 



OUT OF SPECIFICATION 



I 



Wiring circuit from main switch to bulb sock- 
et connector is faulty, repair. 



7-46 



ELEC 



B-r ( - ) 



7-47 



TRBL 
SHTG 


9 

• 



STARTING FAILURE/HARD STARTING 
TROUBLESHOOTING 

NOTE: 

The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, 
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, 
adjustment and replacement of parts. 



STARTING FAILURE/HARD STARTING 

FUEL SYSTEM PROBABLE CAUSE 

— Fuel tank 



— Fuel cock- 



— Carburetor- 



•Empty 
•Clogged fuel filter 
♦Clogged fuel breather hose 
•Deteriorated fuel or fuel containing water or 
foreign material 

•Clogged fuel hose 

•Deteriorated fuel, fuel containing water or 
foreign material 
•Clogged pilot jet 
•Clogged pilot air passage 
•Sucked-in air 

• Deformed float 
•Groove-worn needle valve 

• Improperly sealed valve seat 
•Improperly adjusted fuel level 

• Improperly set pilot jet 

• Clogged starter jet 

• Malfunctioning starter plunger 



Air cleaner- 



• Clogged air filter 




• 



8-1 



STARTING FAILURE/HARD STARTING 



ELECTRICAL SYSTEM 

— Spark plug- 



— Ignition coil 



— CDI unit systenr 



— Switches and wiring' 



Starter motor ■ 



L- Battery 



COMPRESSION SYSTEM 

— Cylinder and cylinder head 



— Piston and piston rings ■ 



— Crankcase and crankshaft' 



Valve train 



TRBL 
SHTG 


9 

• 



PROBABLE CAUSE 

-•Improper plug gap 
•Worn electrodes 
•Wire between terminals broken 

• Improper heat range 
-•Faulty spark plug cap 

-•Broken or shorted primary/secondary 

• Faulty spark plug lead 
-•Broken body 

-•Faulty CDI unit 
•Faulty source coil 

• Faulty pick-up coil 

1 — • Broken woodruff key 



•Faulty main switch 
•Faulty "START" switch 
•Faulty "ENGINE STOP" switch 
•Faulty "NEUTRAL" switch 
•Broken or shorted wiring 

•Faulty starter motor 

•Faulty starter relay 

♦ Faulty circuit cut-off relay 



■•Faulty battery 

PROBABLE CAUSE 

■•Loose spark plug 
•Loose cylinder head or cylinder 

• Broken cylinder head gasket 
•Broken cylinder gasket 

•Worn, damaged or seized cylinder 

• Improperly sealed valve 

•Improperly contacted valve and valve seat 
•Improper valve timing 
••Broken valve spring 

■•Improperly installed piston ring 
•Worn, fatigued or broken piston ring 
•Seized piston ring 
•Seized or damaged piston 



C •Improperly seated crankcase 



'Seized crankshaft 



1 — •Improperly adjusted valve clearance 
' — •Improperly adjusted valve timing 



8-2 



POOR IDLE SPEED PERFORMANCE/POOR MEDIUM 

AND HIGH SPEED PERFORMANCE 



TRBL 
SHTG 


9 

• 



POOR IDLE SPEED PERFORMANCE 

POOR IDLE SPEED PERFORMANCE 

— Carburetor 



— Electrical system' 



— Valve train' 



PROBABLE CAUSE 

-•Improperly returned starter plunger 
•Clogged or loose pilot jet 

• Clogged pilot air jet 
•Improperly adjusted idle speed 

(Throttle stop screw) 

• Improperly adjusted throttle cable play 
-•Flooded carburetor 

-•Faulty battery 
•Faulty spark plug 
•Faulty CDI unit 
•Faulty pickup coil 
' — • Faulty ignition coil 

-•Improperly adjusted valve clearance 



■—Air cleaner- 



'Clogged air filter 



POOR MEDIUM AND HIGH SPEED PERFORMANCE 



POOR M 



EDIUM AND HIGH SPEED PERFORMANCE 

— Refer to "Starting failure/ Hard starting". 
{Fuel system, electrical system, compression system and valve train 

PROBABLE CAUSE 

— Carburetor 



*— Air cleaner- 



Improper jet needle clip position 
'Improperly adjusted fuel level 
'Clogged or loose main jet 

'Clogged air filter 



8-3 



FAULTY GEAR SHIFTING/ 
CLUTCH SLIPPING/DRAGGING 



TRdL 
SHTG 


9 

• 



FAULTY GEAR SHIFTING 

HARD SHIFTING 

Refer to "CLUTCH DRAGGING". 
SHIFT PEDAL DOES NOT MOVE 

-Shift shaft 



— Shift cam and shift fork- 



— Transmission' 



— "S'hift guide' 



JUMP-OUT GEAR 

— Shift shaft- 



Shift fork- 



— Shift cam 



*— Transmission 



CLUTCH SLIPPING/DRAGGING 

CLUTCH SLIPPING 

— Clutch 



•—Engine oil 



PROBABLE CAUSE 

-•Bent shift shaft 

-•Groove jammed with impurities 
• Seized shift fork 
' — »Bent shift fork guide bar 



-•Seized transmission gear 
•Jammed impurities 
1 — ♦Incorrectly assembled transmission 

-•Broken shift guide 

PROBABLE CAUSE 



I— • 



Improperly adjusted shift lever position 
Improperly returned stopper lever 



•Worn shift fork 



n 



•Improper thrust play 
Worn shift cam groove 



•Worn gear dog 



PROBABLE CAUSE 

•Loose clutch spring 
•Fatigued clutch spring 
•Worn friction plate 
•Worn clutch plate 
•Incorrectly assembled clutch 

•Low oil level 

•Improper quality {Low viscosity) 

•Deterioration 



8-4 



OVERHEATING/FAULTY BRAKE 



TRBL 
SHTG 


9 

• 



CLUTCH DRAGGING 

-Clutch 



•—Transmission oil 



OVERHEATING 

OVERHEATING 

Ignition system' 



— Fuel system 



— Compression system 

— Engine oil 



•—Brake* 



FAULTY BRAKE 

POOR BRAKING EFFECT 

•—Disc brake 



PROBABLE CAUSE 

•Warped pressure plate 

• Unevenly tensioned clutch springs 
•Match marks not aligned 
•Loose clutch boss nut 

• Burnt primary driven gear bushing 
•Bent clutch plate 

•Swollen friction plate 

• Broken clutch boss 

•High oil level 

•Improper quality (High viscosity) 

•Deterioration 



PROBABLE CAUSE 

•Improper spark plug gap 
•Improper spark plug heat range 

• Faulty CDI unit 

•Improper carburetor main jet 
(Improper setting) 

• Improperly adjusted fuel height 
•Clogged air cleaner element 



-•Heavy carbon build-up 

-•Incorrect oil level 
•Improper oil viscosity 
' — •Inferior oil quality 

-•Dragging brake 



PROBABLE CAUSE 

•Worn brake pad 
•Worn brake disc 
•Air in brake fluid 
•Leaking brake fluid 

• Faulty cylinder kit cup 
•Faulty caliper kit seal 

• Loose union bolt 
•Broken brake hose 
•Oily or greasy brake disc 
•Oily or greasy brake pad 
•Improper brake fluid level 



8-5 



SHOCK ABSORBER MALFUNCTION/ 
INSTABLE HANDLING/FAULTY LIGHTING SYSTEM 



TRBL 
SHTG 


9 

• 



SHOCK ABSORBER MALFUNCTION 

MALFUNCTION 

I 



INSTABLE HANDLING 

INSTABLE HANDLING 

— Handlebars 



— Steering 



— Tires ■ 



— Wheels- 



— Frame- 



*— Swingarm- 



FAULTY LIGHTING SYSTEM 

HEADLIGHT DARK 

I 



BULB BURNT OUT 
I 



PROBABLE CAUSE 

•Bent or damaged damper rod 
• Damaged oil seal lip 
•Fatigued shock absorber spring 



PROBABLE CAUSE 

•Improperly installed or bent 

•Incorrect toe-in 

• Bent steering shaft 
•Improperly installed steering shaft 
•Damaged bearing or bearing race 
•Bent tie-rods 
•Deformed steering knuckles 

•Uneven tire pressures on both sides 
•Incorrect tire pressure 
•Unevenly worn tires 

•Deformed wheel 
•Loose bearing 
•Bent or loose wheel axle 
■•Excessive wheel run-out 

■•Twisted 

• Damaged frame 

L— • Improperly installed bearing race 

Worn bearing or t 
Bent or damaged 



C»Worn bearing or bush 
• l 



PROBABLE CAUSE 

■•Improper bulb 
•Too many electric accessories 
•Hard charging (Broken charging coil and/or 

faulty rectifier/regulator) 
•Incorrect connection 
•Improperly grounded 
•Poor contacts (main or light switch) 
•Bulb life expired 

PROBABLE CAUSE 



-•Improper bulb 

•Faulty battery 

•Faulty rectifier/ regulator 

•Improperly grounded 

•Faulty main and/or light switch 

1 — »Bulb life expired 
8-6 






I- 

9 



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o ::::::::::::::::: : 

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a ::::::::::::::::: : 

o : '■ ■* J????--^l-- | 



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CD 
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5 

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>• 



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